Have you ever wondered about the role of assist gases in fiber laser cutting and which one can give you the best results? In the world of precision cutting, the choice of assist gas can make a significant difference in both productivity and quality. To explore this, a study was conducted comparing air, oxygen and nitrogen assist gases with mixed gas for cutting mild steel of 6mm thickness over a year. The results are compelling, showing how mixed gas outperforms the others, delivering better results in less time. But first let us know what assist gases and mixed gas are!
Assist Gas
In laser cutting, assist gas plays a crucial role in enhancing the cutting process. When a laser beam cuts through a material, an assist gas is directed onto the cutting zone through a nozzle. The assist gas helps to blow away molten material and debris from the cutting area, ensuring a clean cut and preventing the material from re-solidifying on the edges.
The choice of assist gas can influence the speed and quality of the cut.
Mixed Gas
In the last two to three years, mixed gas has made it possible to cut almost any material. Mixed Gas is a type of assist gas that significantly increases the quality and speed of cutting for various metal thicknesses. The main benefit of cutting with mixed gas is to minimize burrs or dross on the material. As a result, we can easily jump into the next production process step.
By combining the advantages of each cutting gas—nitrogen for fast cutting and oxygen for cutting without burrs or dross—we have produced a single cutting stream that cuts rapidly and nearly completely without any burrs or dross.
In order to achieve an oxide-free and smooth surface by laser cutting one should use mixed gas. While it can be challenging to obtain high-quality parts from low-quality material, our use of mixed gas enables you to achieve the excellent process results you need.
Video highlights of a comparative study
Through a series of tests done in one year, this study reveals how mixed gas not only enhances cutting speed but also ensures superior cut quality, resulting in increased productivity and reduced need for post-processing. These findings underscore the substantial advantages of using mixed gas in laser cutting operations.
- Mixed Gas vs. Air: A Speed and Quality Comparison: When comparing mixed gas to air, two samples of the same thickness were cut separately using each gas. The mixed gas completed the cut in just 0.07 seconds, while air took 0.09 seconds. Although this difference may seem small, it accumulates significantly over time. Moreover, the cut quality with mixed gas was flawless, with no burrs or dross, leading to an increase in overall productivity and reduced post-processing time.
- Mixed Gas vs. Nitrogen: Superior Quality in Every Cut: In the next comparison, mixed gas and nitrogen were used to cut two samples of same thickness. Both gases took 0.07 seconds to complete the cut. However, the mixed gas once again proved superior, delivering a cut free of burrs or dross, compared to the nitrogen cutting. The flawless result achieved with mixed gas translates into less need for rework and a higher-quality end product.
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- Mixed Gas vs. Oxygen: Cutting Time and Productivity Advantage: The final comparison between mixed gas and oxygen revealed even more significant differences. While mixed gas took 0.07 seconds to cut the sample, oxygen required 0.12 seconds. This improvement not only saved time but also boosted productivity by a staggering 1.7 times with no oxidation.
- Yearly Productivity: The Results Are Clear: When examining yearly productivity, the advantages of mixed gas become even clearer. Over a year, using oxygen as the assist gas produced 26,28,000 pieces. In contrast, mixed gas enabled the production of 45,05,143 pieces—an increase of 18,77,143 pieces, equating to 1.7 times boost in productivity.
Similarly, when comparing mixed gas to air, the numbers were just as impressive. Air produced 3504000 pieces, while mixed gas again led to the production of 45,05,143 pieces—an increase of 10,01,143 pieces, or a 28% rise in productivity.
As for nitrogen and mixed gas, both had the same cycle time, but the quality differed significantly. Mixed gas produced flawless cuts with no burrs or dross, while these imperfections were still observed when using nitrogen gas.
The difference between these gases
Using mixed gas, you will be able to produce 28% more sample pieces compared to air gas. Using mixed gas, you will be able to produce 1.7 times more sample pieces compared to oxygen gas. Using mixed gas, you will get flawless cuts with no burrs or dross compared to nitrogen gas.
How easily can it cut Mild Steel?
The most common case in the industry is mild steel laser cutting. Utilizing mixed gas will increase production efficiency. Laser cutting using mixed gas increases production by 1.7 times quicker than cutting with oxygen. As the edges have no burrs or dross or imperfections, one can directly start the next production step.
Benefits of Fiber Laser Cutting with Mixed Gas
- Enhanced Productivity: Productivity can be increased, and the project turnaround times can be reduced with the help of Mixed Gas. Our advanced laser cutting technology allows for faster processing while maintaining exceptional cutting quality.
- Effortless Integration: Easily incorporate mixed gas into your existing laser cutting system. Our solution ensures a smooth transition with minimal setup time.
- Reduce Cutting Time: Mixed gas enhances the cutting quality along with reducing cutting time and thus, increasing the productivity when compared to other gases.
- Exceptional Precision: Enjoy cleaner cuts with no burrs or dross. This also ensures high-quality parts with reduced need for further refinement.
- Cost-Efficient: Significantly offers reduction in cutting plan costs and increase in production.
While mixed gas isn’t an ideal solution, it has made some incredibly exciting cutting possibilities possible. As the strength of fiber lasers increases, mixed gases are opening doors for rapid and high-speed cutting.
Conclusion
Mixed gas’s special combination of oxygen and nitrogen is revolutionary. Compared to other well-known forms of laser cutting that employ only nitrogen or only oxygen, mix gas offers a clear advantage.
The above comparative study underscores the advantages of using mixed gas in laser cutting operations. Whether you’re looking for faster cutting times, superior cut quality, or significantly increased productivity, mixed gas emerges as the clear winner. By opting for mixed gas, manufacturers can achieve higher productivity with supreme efficiency, eliminate after process and ultimately produce a higher quantity product in less time.
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