Cutting Reflective Metals with a Laser
Reflective metals, as their name may suggest, are metals which can reflect back wavelengths that are directed at them. Examples of these metals are copper, brass, and bronze. Some of the most reflective metals are aluminium, gold and silver, the latter of which can reflect around 95% of visible light.
This poses an obvious problem for the laser cutting process, which involves a laser beam of heat and light. Below we have explained how you can cut reflective metals using a fiber laser.
Why can there be problems with laser cutting reflective metals?
As mentioned above, a reflective metal can redirect much of what is aimed at it back to the source. Known as ‘flashback’, this can be highly damaging for laser cutting machines should their own lasers end up breaking the equipment.
Some laser cutting machines can cost many thousands of pounds and have expensive replacement parts, so this kind of situation clearly needs to be avoided. Gas laser cutting, the most common type of laser cutting, was founded in 1964 and remains a common form of laser cutting.
Despite this, it has perhaps the most trouble at cutting reflective metals out of any of the other laser cutting processes. This is because it uses beams of lights and mirrors, giving the beam plenty of places to be reflected back into the laser itself.
While some sought to solve this by placing a non-reflective coating on the metal, the molten metal that is created during the laser cutting process is also reflective itself. This means that this can also damage the laser, regardless of how much non-reflective coating you have used. Gas lasers especially struggle with yellow metals such as copper or brass.
However, this isn’t to say that gas lasers can’t work with reflective metals at all, and steps can be taken to complete this process successfully, although there is still the risk of damage. Generally, modern lasers have a failsafe in place by detecting when too much heat is being reflected back into the laser and subsequently shutting it down.
What is the solution for laser cutting reflective metals?
Despite these advancements in technology for gas lasers, it is still not the most efficient method and you are still running the risk of damages. Fiber laser cutting, the most recent advancement in laser cutting technology, is the solution to working with reflective metals effectively.
Rather than using mirrors, gases or delicate lenses, this type of technology uses fibre optic cables instead. This means that reflective metals pose no risk of damaging the fiber laser in the same way that they would do with a gas or crystal laser.
However, it must be noted that fiber lasers are only really effective on reflective metals that are under 5mm in thickness. Any reflective metals that are above this can still be cut using fiber laser cutting, but the speed is slowed down and the quality of the cut is lessened. For these circumstances, waterjet laser cutting is generally recommended as the proposed solution.
Reflective metals are used in many industries around the world, such as the electronics, automotive, aerospace and semiconductor industries, and so it is important that they are cut reliably and with high quality in mind.
Fiber laser cutting reflective metals in action
Considering the above information, here at SPI Lasers we have chosen to only manufacture fiber lasers. Alongside the advantages it poses over gas and crystal laser cutters, fiber lasers also have a longer service life, require less maintenance, are safer, and work at much quicker speeds.
To demonstrate the capabilities of our fiber lasers, we have put together some videos of us laser cutting reflective metals.
Laser cutting tower bridge
Not only did we want to show that our fiber laser cutters can cut reflective metal, we also wanted to demonstrate the intricate and complicated shapes it can create too. So we created a replica model of the iconic Tower Bridge in London.
This is constructed from metals ranging from 1mm thick brass to 10mm thick stainless steel, and cuts at around 5m/min.
Laser cutting a dragon
Another intricate and elegant shape that we wanted to laser cut was a dragon. The project was a complete success, and we managed to make an idea come to life! This was done from a mixture of metals, including brass, copper, aluminium, stainless steel and mild steel. This use of a huge variety of metals demonstrates just how capable our fiber lasers are.
Laser cutting an eagle
Finally, we wanted to create another animal, albeit a slightly less fictional one this time. This came in the form of an eagle. You can see our eagle masterpiece here.
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