Revolutionising the revolutionary

Featuring a carbon composite design, the passenger jet is lighter than rivals, resulting in substantial fuel savings. But the composition of CFRP – in particular, the high heat conductivity of the carbon fibres themselves – makes processing difficult using traditional techniques. Mechanical milling and drilling has been known to cause costly heat damage, chipping, delamination and tool wear. The good news is that much of this damage can be avoided through correct application of laser processing. An ongoing UK study by Rugby-based JK Lasers, in conjunction with Liverpool John Moores University, has revealed that lasers can effectively cut, mill and drill CFRP without compromising the material's integrity.  During trials, a 200W fibre laser (JK200FL) and scanning head were used for trepanning and milling. The JK200FL was also used in cutting and drilling tests using more conventional process heads. Compared to mechanical cutting and milling, the JK200FL's small spot size produced a much cleaner edge and caused minimal thermal damage. In composites of 1mm thickness or more it was used to spiral drill holes, which produced a high quality cut with very slight burn-back that was limited to the top layer of fibres only. A further benefit of using a laser is the fact it's a non-contact material removal process. This means the risk of tool wear is significantly reduced. Mohammed Naeem, worldwide technical key account manager for JK Lasers helped coordinate the research. He said: “CFRP can be used in a wide range of industries to create new products such as the lighter, more fuel efficient Boeing 787. But to fully realise these benefits, the costs and complexity of processing CFRP must be addressed. “The preliminary results of JK Lasers' research in partnership with Liverpool John Moores University, suggest that lasers are more than capable of rising to the challenge. By revolutionising the quality of CFRP processing without compromising the material's strength and stability, lasers will help drive down the costs associated with carbon composite manufacture in the years to come.” www.jklasers.com