Laser Solves Aluminum Fabrication Problems
Aluminum is one of the most widely used engineering metals. This is because it has a high strength-to-weight ratio and is easy to fabricate using various methods. However, there are some challenges you may encounter when working on aluminum workpieces. Aluminum is soft and prone to deformation when cutting with a sharp tool. This can affect the accuracy of the process and the quality of the final part.
The advent of lasers has revolutionized aluminum metal fabrication. With laser technology, you can now process aluminum to get useful components without fear of tool damage and wear. If you are wondering how lasers solve problems associated aluminum fabrication then you are in the right place. This article will explain what aluminum metal fabrication is, common aluminum fabrication problems, and how laser technology solves them.
What is Aluminum Metal Fabrication
Aluminum metal fabrication is the process of turning aluminum material into functional products. It includes techniques such as cutting, welding, machining, and casting to produce various shapes and designs. Aluminum metal fabrication has many benefits which makes it the ideal choice for many projects. Aluminum is lightweight and you will find it easy to handle. It has moderate strength and you can bend, pull, and stretch it without breaking. Furthermore, aluminum has a low cost and retains all its original properties after recycling.
Common Aluminum Metal Fabrication Problems
There are some challenges you may encounter when working on aluminum metal. Aluminum is soft and may wear out cutting tools with time. The following are common aluminum metal fabrication problems.
Cutting Accuracy and Precision
It may be challenging to get accurate and precise aluminum components when using certain techniques. Aluminum leads to a build-up edge where a layer of the material gets attached to the edge of the cutting tool and decreases accuracy. Furthermore, aluminum forms long chips when you are cutting or drilling it. Chip build-up can cause unnecessary vibrations and tool deflection which reduces its ability to make precise cuts.
Heat and Friction
Another problem you can face when cutting aluminum is the generation of excessive heat. The reason behind this is the high thermal conductivity and specific heat capacity of aluminum. Aluminum can transfer heat rapidly from one location to another. Furthermore, the workpiece can continuously absorb heat and become too hot to handle. Excessive heat can damage the cutting tool and affect the mechanical properties of the workpiece.
Discoloration
Discoloration can occur during aluminum welding if you are not careful. The base metals can change color if you don’t maintain the arc length and angle when using any arc welding process like TIG welding. The result is overheating which can change the color of the workpiece. You may also experience some forms of discoloration if you don’t use the shielding gas appropriately. Proper gas coverage will prevent oxidation and unwanted color changes.
Warping and Distortion
You can also experience aluminum workpieces changing shape and form during fabrication. Here, the final part deviates from the original dimension. This occurs when the workpiece expands and contracts rapidly. The buildup of residual stresses can also cause warping and distortion. The force of bending and curling tends to change the internal structure of the aluminum workpiece.
Material Waste and Scrap Generation
Aluminum metal fabrication techniques, especially those associated with cutting with a shear force, generate a considerable amount of waste. You can get waste after cutting off excess materials from a workpiece. Unusable parts as a result of defects and human errors are also a source of waste. A high scrap rate reduces manufacturing efficiency and increases production costs. It affects your ROI and makes it challenging to maintain competitiveness.
How Laser Technology Solves Aluminum Fabrication Problems
The development of lasers was a breakthrough to many manufacturing problems. It has many advantages over traditional operations and produces better results. The following are ways laser technology helps to solve issues associated with aluminum fabrication.
Automation
Laser cutting is an automated process controlled by CNC technology. With lasers, you can be sure of more accurate and precise final parts. This is because the CNC system controls the movement of the laser beam and allows you to monitor the operation in real-time. You can make changes as needed to get the highest cut quality. Laser systems result in low scrap rates and save costs.
Non-Contact Process
A CNC laser system does not need to make physical contact with the aluminum workpiece for it to function. This noncontact feature will help you control the amount of heat input to avoid overheating. Furthermore, there is nothing like tool marks that can affect the quality of the final part. All these prevent contamination and extend tool life.
Reduces Finishing Requirements
You can produce clean cuts and strong welds with laser systems. Laser cuts and welded joints are free from errors and irregularities. When cutting, the highly focused laser beam removes material slowly and prevents mistakes. All these reduce the need for deburring and secondary operations.
Design Flexibility
Laser systems can cut complex shapes and intricate designs that would have been difficult with conventional methods. All you need to do is to create the final shape of the cut using software tools. With lasers, you can easily make design changes at a low cost. Furthermore, laser systems allow for easy customization of parts. You can create components according to individual clients’ requirements.
Production Efficiency
Laser processing methods increase production efficiency in many ways. Because they are automated, they cuts and welds aluminum workpieces at a high speed. This reduces processing time making them suitable for mass production of parts. Additionally, you can work on both thin and thick metal raw materials. All you need to do is adjust the laser parameters based on the metal thickness.
Laser Processes for Aluminum Fabrication
There are different laser operations you can use for aluminum metal fabrication. The following are the major ones.
Laser Cutting
You can use lasers to cut aluminum parts. This process is suitable for manufacturing aerospace parts, automotive components, and medical devices. Rather than cutting, a high-power laser beam melts or burns through the metal in a predetermined pattern. You then use a high-pressure steam of gas to blow the molten material away from the cut area. When cutting aluminum, go for fiber lasers. This laser type has a shorter wavelength which allows for better absorption by aluminum.
Laser Welding
Lasers are perfect for joining two or more aluminum parts together. As the laser beam comes in contact with the joint, it melts and forms a weld pool. The materials mix as they cool and solidify creating a strong weldment. You can carry out this process with or without a filler material. However, the filler metal should match the chemical composition and properties of aluminum to prevent welding defects. Furthermore, you can also use laser systems for dissimilar material welding. Aluminum is compatible with stainless steel, copper, and titanium.
Laser Drilling
You can also use high-energy lasers to ablate aluminum workpieces and drill holes into them. The process of laser drilling is exceptionally accurate and precise. It is fast and does not use physical drill bits that can break or wear out with time. However, aluminum has high reflectivity and can absorb the laser beam, which limits its function. Additionally, laser drilling works best with aluminum sheets that are less than 15mm thick.
Laser Marking and Engraving
Marking and engraving are one of the terminal steps in aluminum metal fabrication. It is possible to engrave logos, texts, designs, and barcodes on aluminum workpieces using lasers. This allows you to easily track and trace a part. Furthermore, laser marking is a good way to customize components. Personalized logos help to reinforce your company’s brand identity. Note that marking is different from engraving. Laser marking involves little or no penetration. However, engravings penetrate below the workpiece surface and remove a portion of it.
Conclusion
Laser technology has many applications across diverse manufacturing industries. You can use it to weld thin-walled electronic components and for shipbuilding. Additionally, laser operations are indispensable in manufacturing architecture features like facades and automotive components such as cylinder heads and bumpers.
To make the most use of laser technology for aluminum fabrication, it is important to use a reliable service provider. A good laser contact manufacturer will ensure consistency in production and get your products to market on time. For top-notch laser services and quality cutting solutions, contact Zintilon. Our experts are ready to attend to all your manufacturing needs.
