Laser Processing of Light Metals

Aluminium is lighter than titanium: While the density of titanium is 4.51 grams per cubic centimeter, that of aluminium is 2.7 grams per cubic centimeter. However, both materials have unique properties, such as titanium’s corrosion resistance on the one hand and aluminium’s high strength on the other. To combine these advantages, a titanium-aluminium alloy is ideal—these are known as titanium aluminides. 

The advantages of titanium lie in its properties, as mentioned earlier: heat resistance and fatigue resistance are just as important here as its high strength-to-weight ratio and specific gravity. Engine and landing gear components, in particular, benefit from these properties. In addition, a wide range of aviation components can be manufactured using titanium. The manufacturing process relies on both mechanical machining—such as the precision bending of titanium sheet metal—and laser cutting of titanium. 

Laser processing of titanium and aluminium involves various techniques that are largely determined by the properties of the materials. Both titanium and aluminium—frequently used in the aerospace and medical technology industries—require specific adjustments during laser cutting, engraving, and polishing.

1. Titanium Laser Cutting:

• Laser Requirements: Titanium is characterized by high strength and heat resistance, which requires higher laser power during cutting. This enables precise cutting, which is crucial for applications in high-precision industries such as medical technology.
• Heat-Affected Zone: Titanium’s high thermal capacity results in a relatively narrow heat-affected zone, which helps minimize warpage and improve surface quality.
• Laser Engraving of Titanium: Titanium is well-suited for laser engraving, producing durable, high-contrast markings. This is particularly important for components that must withstand high stresses while remaining identifiable.

2. Laser Cutting of Aluminium:

• Reflectivity: Aluminium is a highly reflective material, which requires special precautions when laser cutting it. The laser power, feed rate, and focal length should be optimized according to the material thickness. In addition, fiber lasers or pulsed lasers are used to reduce reflection and ensure consistent cut quality.
• Cutting speed and energy consumption: Aluminium can be cut faster and with less energy than titanium. This is advantageous for the large-scale manufacture of components and enables more efficient production.
• Laser engraving of aluminium: Compared to titanium, aluminium is also easy to engrave. However, due to its reflective surface, a higher power setting is often required to achieve similar depth and contrast.

3. Laser Polishing of Aluminium:

• Surface Finish: Laser polishing of aluminium is a popular technique for achieving smooth, glossy surfaces. Aluminium responds well to the laser’s energy, which enables the creation of high-quality surfaces—important for applications where appearance and corrosion resistance are key.
• Advantages in finishing: This method reduces the need for mechanical post-processing, saves time, and simultaneously improves the surface texture. Laser polishing of aluminium is used particularly in the automotive industry to create surfaces that are both aesthetically pleasing and functional.

In general, conventional laser cutting processes for aluminium allow for component accuracy within a tolerance range of ± 0.1 millimeters—depending on the size and material thickness, even much tighter tolerances can be achieved. Laser fine cutting of light metals offers the highest precision for machining thin materials, even with aluminium.

The exact costs depend on various factors, such as the materials selected and the desired processing method. We can process materials you provide, but we also offer our own material service as an alternative.

Once you’ve selected the appropriate materials, we’ll assist you with a wide range of processes, such as laser processing of light metal foils or laser marking of various surfaces.