Effect of lay-up configuration and processing parameters on surface quality during fiber laser cutting of CFRP laminates

Experimental data is presented relating to heat-affected zone (HAZ) and surface quality when using continuous wave (CW) fiber laser cutting carbon fiber reinforced plastic (CFRP) with varying configurations including + 45°/− 45°, 0°/90°, and plain woven. The effect of typical cutting parameters including laser power, cutting speed, and assist gas pressure on laser cutting quality of different type of workpiece materials was investigated. A full factorial experimental array was employed involving 24 trials. The statistical significance of individual cutting parameters was determined using main effects plot together with ANOVA. Results showed that the fiber laser was feasible for cutting CFRP with very high efficiency. The HAZ level of laser cutting CFRP was highly related to fiber orientation, laser power, and cutting speed based on theoretical and statistical analysis. Thermal model was built to simulate HAZ values recorded on the exit surface. The calculated results were close (within ~ 60 μm) to the experimental results. The lowest HAZ value of 707 μm and surface roughness of 2.43-μm surface roughness were achieved in cutting Type 1 (+ 45°/− 45°) configuration. High-resolution SEM and optical micrographs showed that cracks, cavities, delamination, and matrix decomposition were the typical defects observed in CW fiber laser cutting of CFRP laminates.