Metal laser cutting machine in the use of aluminum cutting
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The advantage of laser cutting is that it can quickly and accurately process aluminum foil into different shapes. This technological advantage has just attracted many airlines for the commercialization of laser cutting equipment. In the 1970s, major manufacturers evaluated laser cutting techniques and found that the microfissures produced by laser processing do not allow damage to the part's fatigue properties. Potential gains hurt the interests of the manufacturing industry, and laser cutting technology has been shelved by major airframe manufacturers.
Rotary parts and transmissions are manufactured using forged large metal billets. The fuselage also contains some parts that use forged materials, but most of the fuselage parts use aluminum plates. Traditionally, 7000 series zinc-based aluminum alloys have been used for processing because of its good static strength and fatigue strength. Although 7000 series aluminum materials are very suitable for aerospace applications, they are not resistant to high temperatures. Rapid heating, such as welding and laser cutting, can cause micro-cracks. Micro-cracks result in a decrease in fatigue strength. Welding and laser cutting are two processes that produce thermally induced micro-cracks.
Quality and process control are crucial. Any process that brings uncertainties to processing must be controlled or eliminated directly. In the past, laser cutting brought great challenges to quality control and consistency between different production batches.
In current laser cutting systems, the limitations of these laser cutting in aerospace applications have been improved. These limitations include problems with fatigue performance and reduced consistency of the manufacturing process. The laser system now largely reduces the size of the heat affected zone (HAZ) and the corresponding microcracking. During the laser cutting process, the technician can already control the cutting parameters and use the calculator software to make precise repetitions. These technological advances have led to a rethinking of whether laser cutting is suitable for the production of fuselage structures. The fuselage structure is mainly made of 7000 series aluminum materials.
Fatigue fractures typically occur where stress is concentrated, such as at the edge of a part, at a change in geometry, or at a joint. There are many different ways of joining body parts made of sheet metal, and most of the fatigue cracks occur at the joints. If the laser is not used to cut small holes in the joint, the laser is mainly used for edge cutting of the part. For other effects, the most vulnerable joint location can be used to illustrate the micro-cracking and non-major damage from laser cutting compared to the joint. In this way, we can conclude that if a part is likely to break at the joint, laser cutting technology will not further damage the fatigue characteristics of the part.
The laser cutting process can process consistent parts faster and it is more efficient than traditional machining. Laser technology is expected to reduce processing time and production costs. For a long time, in the processing of 7000 series aluminum plates, the advantages of lasers have not been exerted due to the reduction of fatigue performance. Recently, the innovation of the laser system has led people to re-evaluate the advantages of laser cutting aerospace aluminum. Preliminary tests have demonstrated the potential of laser technology in airframe processing. Future airframe systems and existing designs should not rule out the possible application of lasers in the airframe system because of past experience. We should keep an open mind to analyze various situations to determine whether laser technology can bring product benefits.
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