Dross formation during laser cutting process

Melt formation during laser cutting of metallic substrates is considered and the melt thickness is formulated using a lump parameter analysis. The droplet diameter is also predicted and compared with the experimental results. A CO₂ laser with variable pulse frequency is used in the experiment. Oxygen, as assisting gas, impinging coaxially with the laser beam, is used at different pressures. SEM and XRD are carried out to obtain micrographs and oxide compounds formed in the dross. It is found that the liquid layer thickness increases with increasing laser output power and reduces with increasing assisting gas velocity. The droplet formed is spherical and the droplet size predicted agrees well with the experimental results.