FACTS ABOUT

Cutting of aluminium

CONTENTS
Introduction ........................................................................... ....... 3
Process comparison ......................................................................3
Mechanical cutting ....................................................................... 4
Plasma cutting ............................................................................. 5
Introduction .................................................................................. 5
Principle ....................................................................................... 5
Gas selection ............................................................................... 6
Dry plasma cutting ...................................................................... 6
Underwater plasma cutting ......................................................... 6
Cut quality ..................................................................................... 7
High tolerance plasma arc cutting .............................................. 8
Equipment ................................................................................... 8
Future developments .................................................................. 8

Health and safety in plasma cutting ....................................... ..... 9

Hazardous gases . ................................... .....................................9
Fume ............................................................................................ 9
Noise............................................................................................. 9
Optical radiation .......................................................................... 9
Safety precautions - machine plasma cutting .......................... 10
Safety precautions - manual plasma cutting ............................ 10
External environment ................................................................ 10

Laser cutting .............................................................................. 11

Introduction ................................................................................ 11
Principle ...................................................................................... 11
Gas selection .............................................................................. 12
Water jet cutting ......................................................................... 14
Environment ............................................................................... 14
Gouging ...................................................................................... 14
Mechanical gouging ................................................................... 14
Plasma arc gouging .................................................................... 14
Finishing operations ................................................................... 15
Grinding ...................................................................................... 15
Bevelling ...................................................................................... 15
Working environment ............ ..................................................... 15
2

INTRODUCTION / PROCESS COMPARISON

Introduction

Process comparison

Cutting into size and shape as well as gouging are different

for aluminium compared to steel. One of the most popular
methods of cutting steel is oxy-fuel cutting but this cutting
process is not applicable for aluminium. This is due to the
oxide layer on the metal which acts as a refractory skin. The
oxide also has a melting point (2052C) of more than three
times that of the base metal (660C). The heating action of
the ame in oxy-fuel cutting melts the base metal well
before the oxide melts, which in turn results in very crude
cuts.

A general process comparison for different cutting

methods available for aluminium can be made. This
comparison can be made on a basis of general suitability
for aluminium, representative cutting speeds, thickness
ranges, cut quality and exibility. The suitability (see Table
1) is based on weighing all other factors stated above and
on the state of the art technology available today.

Cutting method
Gas/oxy-fuel cutting
Plasma cutting
Mechanical cutting
Water jet cutting
Laser cutting

Suitability
Not possible
++
++
+
+

++ excellent, + good
Table 1. Comparison of different cutting methods for aluminium.

The representative cutting speeds (see Table 2) depend on

the quality of the cut. A higher cutting speed results in
rougher cuts.

Cutting method

Cutting speed (mm/min)

t=2mm
t= 40 mm

Plasma cutting
Laser cutting
Water jet cutting

> 600
5000
800

Comments

1200
Ar/H2, 240A
not possible CO2, 2600W
80

Table 2. Representative cutting speeds (mm/min).

The thickness ranges possible for different methods also

depend on required quality of cut. Thicker plates also
demand other cutting parameters.

Cutting method
Plasma cutting
Laser cutting
Water jet cutting

Thickness range (mm)

0.8 - 200
0.1 - 8
1.5 - 100

Table 3. Thickness ranges.

MECHANICAL CUTTING

The cut quality needed is based on what type of operations

the sheet, plate or prole will undergo after cutting.
Different welding methods demand different t-ups of the
joints for example.

Criterion

Plasma cutting

Laser cutting

Water jet cutting

+/-/0
+

++
++
+
0

+
+
++
--

+
+

++
+
-

++
--

Cut quality
Surface roughness and unevenness
Kerf width
Width of the heat affected zone
Cutting speed (6 mm)
Flexibility
Contours: sharp edges
3-dimensional cutting
Investment costs

++ excellent, + good, 0 fair, -poor, --insufcient performance

Table 4. Qualication of different cutting methods.

Mechanical cutting
Mechanical cutting is in many cases very economical and
versatile. Aluminium can be worked with common
machine tools found in most fabricating shops.
Aluminium is often compared with wood because the same
tools work for both materials and at roughly the same cutting speeds. The main difference lies in that aluminium
demands more power to maintain the cutting speeds. Even
at high cutting speeds lubricants or coolers are not
needed.

are necessary to achieve high cutting speeds and good

surfaces. The following are recommended blade surface
speeds:

2400 m/min for high speed steel circular blades.

3600 m/min for tungsten carbide tipped circular blades.
1500 m/min for band saw blades.

Saws are versatile tools when cutting to size and shape as

well as for bevelling aluminium. Portable band saws do not
permit the high blade speeds necessary and oor mounted
saws are therefore more suitable. Effective sawing of aluminium is dependent on three main factors: the blade
speed, tooth shape and tooth spacing. High blade speeds

Adequate tooth spacing is normally 1-1.5 teeth per cm. A

rule of thumb is that no more than 2-4 teeth should be in
the cut surface at one time.

PLASMA CUTTING

Plasma cutting
Introduction

Principle

The plasma arc cutting process is a highly productive method

of cutting aluminium and is experiencing rapidly growing
application.

Plasma cutting is a melting process, compared to ame cutting

which is a combustion process. A gas jet in the plasma melts
and expels the material from the kerf. During the process an
electric arc burns between an electrode and the workpiece.
The electrode tip is placed in a water or air cooled gas nozzle
in the torch. The plasma gas is conducted through the nozzle.
The arc and the plasma gas are forced to pass through a very
narrow orice in the tip of the nozzle. The gas is heated and
ionised. The concentrated plasma jet which is formed has a
temperature of up to 30 000C together with a high velocity.
When the plasma jet hits the workpiece the heat is transferred
due to recombination (the gas reverts to its normal state). The
material melts and is expelled from the kerf by a ow of gas.

Cuts can be made from thick foil thickness up to 200 mm

although cutting in these thicknesses causes extreme noise
levels that have to be taken into consideration when considering the suitability of the process.
Plasma cutting was developed in the 1950s for severing steel
sheet and plate. Today, it is used on nearly all types of conducting engineering materials. One limiting factor for the plasma
process has been the high investment costs.
The trend today is that more simple and inexpensive machinery
is used, making plasma cutting a realistic alternative to other
cutting methods.

To initiate the process, and ionise the gas, a pilot arc must be
generated. The pilot arc heats the plasma gas and ionises it.
Since the electrical resistance of the main arc is lower than
that of the pilot arc, the main arc ignites and the pilot arc
automatically extinguishes.

Figure 1. The principle of plasma cutting.

GAS SELECTION / DRY PLASMA CUTTING

Gas selection

Dry plasma cutting

The selection of gas or gases for plasma arc cutting of aluminium is based on such factors as the required quality of
the cut, the thickness of metal to be cut and the gas cost.
For cutting thin metal a single gas ow is often used to
provide both the plasma and the arc shielding, but for cutting thicker metal, dual gas ows are used. The single gas
ow may be air, nitrogen or argon. The dual gas ows may
be nitrogen, argon or argon/hydrogen mixtures. For medium
and thick metal, nitrogen or argon/hydrogen mixtures are
used as the plasma gas.

The best results are obtained with plasma gas consisting

of 80% argon and 20% hydrogen. Cutting with a nitrogen
and argon mixture results in a larger heat affected zone
than cutting with argon and hydrogen mixture, see
Figure 2.
When cutting with a 80% argon and 20% hydrogen mixture,
the surfaces are smooth and nely cut with practically no
dross formation. The cutting speed is of crucial importance.
One problem when cutting aluminium is the formation of
light weight particles that can travel a long way from the
cutting table. These can be taken care of with a good
ventilation system.

The maximum currents for different plasma gases:

Nitrogen 600A (Underwater cutting of aluminium)
Ar/H2

1000A (Dry plasma cutting of aluminium)

Air

300A

The suitable current range for manual cutting is 20A-100A

and for mechanised 100A-1000A.
The effect of the cutting gas on the heat affected zone is
shown in Figure 2. The HAZ is increased with increasing
thickness but it is also increased when by using a N2 - Ar
gas mixture instead of a H2 - Ar mixture.

Underwater plasma cutting

Plasma cutting under water has been used for many years.
The advantages of under water plasma cutting are numerous.
Arc glare and noise are cut down to a level where no
operator protection is needed. Fumes generated are reduced
compared to conventional plasma cutting.
Nitrogen is used for underwater plasma cutting of aluminium. If oxygen is used, the surface becomes heavily
oxidised. One problem with underwater cutting of aluminium is that there is a risk of hydrogen detonation. The
actual cause of these detonations is believed to be the interaction of molten aluminium and water. The hydrogen can
accumulate in pockets under the workpiece and ignite when
the cutting arc passes near or over a pocket. If the slag is
removed at specied intervals and water stirring is applied
the risk will be minimised.

Underwater cutting
The advantages:

To consider:

low noise level

hardness of cut surface
less visible radiation careful positioning of plate
less fumes
difcult to supervise the
less dust
cutting process
less deformation
of the plate
Figure 2. Width of HAZ as a function of plate thickness.

Table 5. The advantages and considerations of underwater cutting.

CUT QUALITY

Cut quality
The plasma arc cut edge can be somewhat rough and is not
perfectly square. While manually made plasma arc cuts can
be fairly smooth, the best results are made with the mechanised process where higher currents and travel speeds are
possible. Cut quality is improved further if water injection
plasma is used.
Plasma arc cutting creates a heat affected zone and some
partial melting of the grain boundaries. The HAZ (heataffected zone) reduces corrosion resistance in the highstrength, heat-treatable alloys such as 2014, 2024 and 7075
(AA classication). Due to this it may be necessary to remove
some or all of the heat affected zone by mechanical means
for certain applications.
The alloy and temper of the plasma cut plate inuence the
width of the heat affected zone. Figure 3 shows the relative
microhardness as a function of the distance of the plasma
cut edge.

The partial melting of the grain boundaries can result in

microcracking in the cut edges. The 2XXX, 6XXX and 7XXX
series (heat-treatable) are particularly sensitive to hot cracking whereas the 1XXX, 3XXX and 5XXX series (non-treatable) alloys are not so sensitive. The tendency to crack
increases with metal thickness because the thicker metal
imposes greater restraint on the solidifying metal.
Many standards for fabricating aluminium require that
both the roughness and the cracked zone must be removed
by machining the plasma cut edges to a depth of about 3
mm. This is of particular interest when the metal is to be
stressed dynamically. The quality of cut is dependent on
several factors. The alloy for instance: the 6XXX series alloys
give smoother cuts than the 5XXX series alloys. The cutting
speed plays a role because either excessive or too low speed
reduce the cut quality. High arc voltage and high gas ows
both increase cut squareness.

The quality of a plasma cut is also affected by the shape of

the electrode. During the process and especially during
start-up the large rating of the electrode causes erosional
wear which results in reduction of the cut quality.

Figure 3. The effect of plate alloy and temper on HAZ microhardness proles.

Other factors inuencing the width of the HAZ is the heat

input during the cut, which is a product of the current
multiplied by the voltage divided by the cutting speed. The
thickness of the plate being cut has also affects the HAZ.
The HAZ width can for example range from 25 mm on a
10 mm thick plate to four times this on a 44 mm plate.

HTPAC

HTPAC
High tolerance plasma arc cutting (HTPAC) was rst
developed in Japan for precision cutting of thin steel sheets
or plates in the range of 0.1 - 6.0 mm. While the conventional plasma cutting process is capable of high productivity
on plate materials, the kerf width and cutting accuracy of
conventional plasma cutting techniques cannot compete
adequately with the high accuracy and narrow kerf width
of laser cutting for sheet and thinner plate materials.

The plasma torches for HTPAC differ from conventional

plasma cutting in the accuracy of the components, and the
way in which gas enters the torch. The accuracy of the cut
is largely dependent on the accuracy of the front end of the
torch. The electrode and the nozzle must be concentric to
ensure the correct gas ow which otherwise will cause the
arc to be displaced from the centre of the electrode. This
will affect dross as well as the angle of the cut.

In an effort to compete with laser cutting, developers of

plasma cutting have striven to nd a system capable of
producing cuts with completely square edges and a narrow
kerf width enabling higher cutting accuracy.

Future developments

Equipment
The HTPAC cutting machine consists of three different
components:
High precision torch
Electronic power source
High precision cutting machine
The torch is probably the most critical part of the plasma
machine, but the development of the system would not
have been possible without new innovations in the other
components.

Figure 4. Three types of HTPAC torches.

Development appears to be concentrating on maintaining

the same quality at higher powers. In the beginning of
HTPAC only 30 A units were available on the market, and
now units up to 130 A are becoming available. The higher
powers will allow thicker materials to be cut together
with increasing the speed of cutting within the present
thickness range.
Regarding capital and running costs, these are typically
half of the costs of laser systems and this means that much
of the growth is expected in areas normally associated with
laser cutting of aluminium alloys. The cutting gases for
aluminium for HTPAC are nitrogen or air as plasma gas
(15 l/min) and methane as shielding gas (20 l/min).

HEALTH AND SAFETY IN PLASMA CUTTING

Health and safety in plasma cutting

The environmental problems usually encountered when
plasma cutting are the formation of hazardous gases and
fume, the high noise level and the optical radiation, which
is very intense. With HTPAC one benet is that the fume
generation is lower due to the narrow kerf because fume
is generally proportional to the amount of metal removed.
With HTPAC one only removes about one fourth of the
amount compared to conventional plasma.
Hazardous gases
The hazardous gases formed in connection with plasma
cutting are nitrogen oxides, ozone and carbon monoxide.
The nitrogen oxides are nitric oxide (NO) and nitrogen
dioxide (NO2). The threshold limit values for theses gases
in Sweden are 25 ppm and 2 ppm respectively. The amount
of nitrogen oxides formed are dependent on the current
and the plasma gas. The higher the current, the higher
the amount of nitrogen oxides. The choice of nitrogen as
plasma gas also increases the amount of nitrogen oxides.
Pure nitrogen is seldom used as plasma gas for manual
cutting. Using air as plasma gas also leads to high amounts
of nitrogen oxides.

Noise
The high exit velocity of the gas produces a high-frequency
noise level of between 8 and 20 kHz.
The factors that affect the noise level are nozzle geometry,
the work metal thickness, plasma gas ow and electric
power. In general it can be said that the noise level
increases with increasing work piece thickness, cutting
gas ow and power.
The noise level in connection with machine cutting,
measured at the operator's ear, is usually around 90-115
dB. Noise levels below 85 dB can only be obtained in
manual cutting with low current. 80 dB is the maximum
noise level normally allowed.
Optical radiation
The high exit velocity of the gas produces a high-frequency
noise level of between 8 and 20 kHz.
Plasma cutting generates high intensity radiation within
both the visible and the DV wavelength ranges.

The amounts of ozone (O3) and carbon monoxide (CO)

formed when plasma arc cutting are normally well below
the threshold limit values. The Swedish threshold limit
value for ozone is 0.1 ppm and for carbon monoxide 35
ppm. The threshold limit values represent the maximum
permissible average concentration for an 8-hour workday.

To protect the operator against glare and skin damage

caused by DV radiation, retinal damage caused by intense
visible light and clouding of the lens of the eye caused
by shortwave IR radiation, the operator must wear fullcoverage clothing and eye protection lenses with a dark
enough shade.

Fume

ISO recommendation for eye safety lenses for plasma-arc

cutting:

The amount of fume is dependent on the plasma gas

used, the material being cut and the coating present on
the material surface.
How dangerous the fume is depends on the material
being cut.

Current lower than

150 A

shade No. 11.

Current

150A -250A

shade No. 12.

Current

250A -400A

shade No. 13

Air and nitrogen produce twice as much fume as argonhydrogen mixtures and considerably more fume than
oxygen.
If the metal surface is painted or is coated with oil or
oxides, it should be cleaned prior to cutting.

HEALTH AND SAFETY IN PLASMA CUTTING

Safety precautions - machine plasma cutting

External environment

In machine cutting the concentrations of fume almost

always exceed the Threshold Limit Value (TLV). Ventilation
is therefore required for all machine cutting.

In order to full the requirement for the quantity of dust

in the extracted air, a textile suppression lter with large
lter area in relation to the volume of air is required. The
reasons for this are the large quantity of dust and the fact
that the particles are extremely small and have a tendency
to block the lter material.

A water curtain around the torch reduces the fume

concentration, but has little effect on the level of nitrogen
oxides.
If cutting is carried out under water the fume concentration
will be very low, but the amount of nitrogen oxides is not
affected since they do not dissolve in water. It is therefore
necessary to cut in well ventilated premises or to use local
extraction.
Other advantages with cutting under water are the
reduction of noise level, radiation density, distortion of
the parts, and the improvement of tolerances. The plasma
process best suited for cutting under water is nitrogen and
oxygen plasma with water injection.
There are other ways to shield off the torch in machine
cutting so that noise intensity is reduced. The extractor
should be positioned underneath the work piece and the
cutting table should be sectionalised in order to obtain
sufcient ow velocities.
Safety precautions - manual plasma cutting
For practical reasons, it is often difcult to arrange
extraction in manual plasma cutting. The formation of
both fume and nitrogen oxides can be reduced drastically
by reducing the cutting current and switching to argonhydrogen mixtures. If an extractor is used, it should be
placed underneath the work piece or in the direction of
the plasma jet.

10

This implies that the cost of the lter is as high as that of

the cutting table in many instances. When it comes to the
limit value in the wate.t; it must not exceed 2.0 mg/l of
aluminium.

LASER CUTTING

Laser cutting
Introduction
Laser cutting is today a well established process in industry.
There are essentially two types of lasers used in materials
cutting - the CO2 laser and the Nd:YAG laser. The CO2 laser
is the most commonly used. The laser medium is a mixture
of gases (CO2, He, N2 ). The Nd:YAG laser is a solid state
laser which means that the laser active medium is a solid
and the Nd:YAG laser does not consume any laser gases.
CO2 lasers with powers in the range of 500W - 3000W are
commonly used for cutting mild steel, stainless steel and
aluminium together with materials such as wood and
plastics. Nd:YAG lasers are being used for welding and
marking more frequently. These lasers usually have lower
powers of 100W - 500W but higher power Nd:YAG lasers
are now available.

The cutting of aluminium with CO2 lasers is considered

difcult due to the high reectivity and high thermal conductivity of the metal. Anodised aluminium is easier to cut
due to the enhanced laser light absorption in the thick
surface layer of aluminium oxide. It is also easier to cut
aluminium alloys than pure aluminium. A high power
laser; preferably over 2 kW, and a good laser mode are benecial to improve the cuttability of aluminium. A small
focal length, about 63 mm, is advantageous for thinner
sheets due to the higher power density in the focal spot.
The maximum thickness which can be cut is 6 - 8 mm.
The Nd:YAG lasers experience a rapid development, and
high power Nd:YAG sources allow speeds of between
2 m/min and 7 m/min on a plate thickness of 3 mm.
Principle
Figure 5 shows the laser cutting process. A laser beam is
transferred to the workpiece and focused onto a small spot.
The heat melts, evaporates or decomposes the workpiece.
The laser beam is surrounded by a nozzle which enables a
ow of cutting gas to ush out the melt or vaporise it.

Figure 5. A laser cutting system.

11

GAS SELECTION

Gas selection
The selection of the cutting gas is dependent on the material to be cut, the required cut quality and cutting speed as
well as the total economy of the cutting process. Aluminium
can be cut with both oxygen and nitrogen as cutting gases
but the cutting speed using oxygen is not signicantly
higher than with nitrogen. The reason for this can be found
in the high melting point for aluminium oxide which is
2072C. The aluminium oxide forms a seal on the cut front,
preventing the oxygen from penetrating to the metal itself.
The oxygen seal frequently bursts as a result of the turbulent
melt ow and the oxidation reaction can still proceed, although at a lower rate.

If high pressure nitrogen or oxygen cutting is used, dross

free cuts can be obtained. It appears that nitrogen is the
best alternative when cutting aluminium alloys, whereas
oxygen is better for pure aluminium. This is demonstrated
by the diagrams in Figure 6 which show parameter ranges
where dross-free cuts are obtained for 2 mm sheets of pure
aluminium (Al99.5) and an aluminium alloy (AlMg3). The
surface roughness is always much higher with oxygen
compared to nitrogen. When high pressure cutting aluminium, the laser beam should be focused close to the lower
surface of the sheet. Typical parameters for cutting AlMg
2.5 are summarised in Figure 7.

Cutting with low oxygen pressure, less than 6 bar, is sometimes used for aluminium cutting. The laser beam should
be focused at the upper surface of the sheet. Standard oxygen is sufcient (~ 99.7% purity) because a higher purity
does not enhance cutting speed. The method results in a
rather rough surface and cut edges with dross.

Figure 6. Dross free parameter ranges when using nitrogen and oxygen for cutting 2 mm pure aluminium and 2 mm aluminium
alloy Laser power 1500 W.

12

GAS SELECTION

Material thickness
(mm)

Laser power
(W)

Nozzle diameter
(mm)

Nozzle stand-off
(mm)

Nitrogen pressure
(bar)

Cutting speed
(m/min)

1.0
2.0
3.0

1500
1500
1500

1.4
1.4
1.4

0.6-0.8
0.6-0.8
0.6-0.8

9
12
15

2.0-5.5
1.3-2.5
0.5-1.1

4.0

1500

1.4

0.6-0.8

15

0.5-0.6

Figure 7. Parameters for laser cutting ofaluminium alloy AIMg2.5. This table applies to dross free cuts. Cutting gas: nitrogen.

In laser cutting the role of the cutting gas is fourfold:

It expels molten and gaseous material from the
cut kerf.
It sometimes reacts exothermally with the metal being
cut and the extra heat accelerates the cutting process.
It cools the sides of the kerf, thus limiting the heataffected zone.
It keeps fume and particles out of the nozzle where
they could contaminate the focusing lens.

13

WATER JET CUTTING / GOUGING

Water jet cutting

Gouging

Water jet cutting exists in two variants, pure water jet cutting and abrasive water jet cutting. Pure water jet cutting
can be used for a variety of non-metallic materials but in
order to cut metals an abrasive is added to the water jet.
The principle is shown in Figure 8. Special pumps are used
to achieve the high pressures needed. The water pressure
can be up to 400 bar.

Mechanical gouging
Most gouging operations are made with mechanical tools.
Straight line gouging is probably best performed using a
rotary cutter machine. A small portable saw can also be
adapted for gouging aluminium by replacing the saw blade
with a cutter which is ground to the required shape.
Tungsten carbide cutters are standard for all types of
mechanical gouging machines. Pneumatic chipping is also
often used although it creates a high noise level in the shop.
This may sometimes be the only way to reach blind corners
and other difcult locations.
Two factors determine the effectiveness of pneumatic
gouging and the choice of gun shape. The gun should be
large enough to provide good solid blows to the chisel and
yet not so large that the operator cannot manipulate it easily.
The other factor is that it should have a round nose rather
than the diamond shape often used on steel.
Plasma arc gouging

Figure 8. Schematics of abrasive water jet cutting.

Environment
The process does not produce any toxic fumes or airborne
dust. Despite this an extraction devise should be placed
under the nozzle to prevent abrasives from spreading into
the surrounding air. The noise levels are high and can reach
up to 100 dB(A) under certain conditions.

14

Gouging aluminium with the plasma arc process is a fairly

recent development. It is very effective and leaves a clean
smooth surface which clearly indicates when the gouging
has reached the sound metal. The nozzle orice has to be
larger than the one for plasma cutting in order to reduce
the plasma jet velocity.
The power source should also have an open-circuit voltage
to permit a long but stable arc. Skills are necessary to achieve
effective gouging. Normally, a maximum groove depth per
pass of 6 mm is preferred but multiple passes are possible.
Mechanised gouging is also possible with this process.

FINISHING OPERATIONS

Finishing operations
Grinding
Grinding is most necessary when spatter from the cutting
needs to be removed. This applies in particular to the parts
that have fallen through the cutting grid and become
exposed to spatter as the cutting continues.
Bevelling
Not long ago, only I-joints were cut in the cutting machine
and the parts were bevel-cut manually. Manual bevel-cutting
involves a great deal of lifting and the operator is subjected
to a lot of fume, since he bends over the part to ensure the
quality. Programmable bevelling units have been available
for the last 7-8 years for plasma and are steadily being
improved. Bevelling directly on the cutting machine saves
machining and intermediate storage.
Working environment
Grinding and manual bevelling cause problems which
express themselves primarily in the form of occupational
injuries such as back ailments and white ngers.

15

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