Journal Pre-proofs

Evaluation of the effect of process parameters on the cut quality in fiber laser
cutting of duplex stainless steel using Response Surface Method (RSM)

Ming Li

PII: S1350-4495(21)00268-1
DOI: https://doi.org/10.1016/j.infrared.2021.103896
Reference: INFPHY 103896

To appear in: Infrared Physics & Technology

Received Date: 9 July 2021

Revised Date: 1 September 2021
Accepted Date: 1 September 2021

Please cite this article as: M. Li, Evaluation of the effect of process parameters on the cut quality in fiber laser
cutting of duplex stainless steel using Response Surface Method (RSM), Infrared Physics & Technology (2021),
doi: https://doi.org/10.1016/j.infrared.2021.103896

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 Evaluation of the effect of process parameters on the cut quality
in fiber laser cutting of duplex stainless steel using Response
Surface Method (RSM)
Ming Li 1,*

1-School of civil engineering, Jilin Jianzhu University, Changchun Jilin 130118, China

* Corresponding author

Email: minglipossess@sina.com

Abstract

Fiber laser cutting of stainless steel material is known as one of the most efficient cutting
methods, with an acceptable quality and low production costs. Duplex stainless steels have
higher chromium and molybdenum contents, making their thermophysical properties
different in comparison to austenitic stainless steels; this can have a direct impact on the cut
quality in the laser cutting process. In this research, the effect of such process parameters as
cutting speed, focal length and laser power on the temperature adjacent to the cut kerf and
cutting surface roughness was systematically investigated through the response surface
methodology (RSM). The central composite design (CCD) was also used for the
experimental design and analysis of variance (ANOVA), showing the effect of the
participation of each factor on the responses. The laser power had the most significant
influence on the temperature around the cut kerf by increasing the temperature from 180 to
500 °C, with the increase of the laser power from 700 to 1100 W. Increasing laser power
continuously diminished the surface roughness about 45 percent. The minimum surface
roughness value was recorded at the focal length of 0.4 mm, at which the laser energy density
was at the highest level of 5100 W/mm2. Increasing the laser power up to 900 W, clearly
improved the roughness although increasing power up to 1100 W has had a detrimental effect
the surface roughness which was led to the creating some cavities and dross at the cutting
surface.

Keywords: Duplex stainless steels, laser cutting, response surface methodology, cutting
surface, surface roughness

1
1.Introduction

Laser cutting is one of the advanced cutting methods. In this method, the accuracy and speed
of cutting are excellent. A high-power laser beam caused by laser radiation is used to cut the
parts in this method. In the recent years, this method has gradually become a practical method
for cutting; so, different studies have addressed the effects of using this method on various
materials. According to the previous reports, this method is used in various industries such as
medicine, marine fields, aerospace, automotive industry and construction, as well as all
industrial tools [1-10]. One of the materials that has been recently considered by scientists in
the laser processes is duplex stainless steels (DSS). These materials have a microstructure
consisting of ferrite and austenite at the ambient temperature, with a combination of the
useful characteristics of both phases. The presence of ferrite increases the tensile strength,
showing good resistance to cracking against the existing stresses. The presence of austenite
also enhances the impact and corrosion resistance [11-14]. Given the novelty of these
materials, few studies have reported the use of these materials in the laser cutting processes.
Therefore, it is important to review some behavioral features of austenitic and ferritic steels
when using this material in the laser cutting processes. Farshidianfar et al. [15], for instance,
investigated the parameters affecting the laser cutting process while cutting 316 stainless
steel. Their results indicated that the width of the kerf was an important parameter in
determining the quality of the cut surface and lowering the cost of the material. Also, by
examining the laser power, focal point position, cutting speed, auxiliary gas pressure and
nozzle standoff, it was found that the most important parameter for forming the shell width
was the position of the laser focal point, which should be on the surface to reach the
minimum possible cut's width. Moreover, increasing the laser power and gas pressure directly
raised the cutting width. Nevertheless, cutting speed and nozzle stand-off distance were
inversely related to the kerf width. In the laser cutting process of 304 austenitic stainless
steel, Atayo et al. [16] obtained the optimal parameters affecting cutting. These parameters
included: laser power above 1000 watts, scanning speed of 8 meters per minute, gas pressure
of 11 bar and the focusing distance of -1 mm. The results also showed that with raising the
laser power at high scan speeds, the cutting width was increased. This was followed by a
decrease in the formation of depressions, an increase of the low temperature in the heat
affected zone and a decrease in the end time.

In another study, Shin et al. [17] investigated the laser cutting parameters of 304 austenitic
stainless steel using underwater laser welding process. Their report confirmed the excellent

2
cutting performance in terms of speed and thickness, even in an underwater environment. By
using such techniques, they were able to cut a 304 sheet with the thickness of 100 mm and a
good quality. Their results also revealed that the use of this method reduced the cutting waste.
In an experimental study, Jadhav et al. [18] also analyzed the effect of laser parameters on the
surface roughness of the cut area of AISI 304 alloy. Their results showed that with increasing
the effective parameters of laser power and gas pressure, the surface roughness was
decreased. It was also found that with raising the laser cutting speed, the surface roughness
was increased. Further, in a review study, Kanyilmaz et al. [19] comprehensively examined
issues related to the heat affected zone, static and fatigue properties, the effect of surface
conditions, cutting geometry and welding geometry on the steel alloys. The results of all
reports show that the laser cutting technology can enable the simple fabrication of Circular
Hollow Section (CHS) joints, thus leading to reduced manufacturing costs and stainless steel
scrap. In laser cutting on stainless steel, Oh et al. [20] also examined the effect of different
nozzle types of lasers on the cutting quality. Their reported the ultrasonic nozzle had a better
performance tolerance for the laser cutting performance of stainless steel. It was also found
that ultrasonic nozzles had the ability to eliminate better melting at longer standoff distances.

In another study, Shin et al. [21] used the fiber laser technology to cut pieces of stainless steel
in an underwater environment. In this study, they improved the cutting quality by reducing
the thickness of the parts, as compared to the previous study [17]. In a laser cutting process,
Kotadiya et al. [22] also cut austenitic stainless steel pieces. The purpose of this study was to
study such process parameters as laser power, gas pressure and cutting speed due to the
surface roughness of the parts. They revealed that the effect of laser power on the cutting
speed and gas pressure was significant. Parthiban et al. [23] also used CO2 laser cutting to cut
304 stainless steel parts. All parameters affecting laser cutting were carefully analyzed. The
effect of the cutting parameter on the quality of the surface cut was further considered by
monitoring the top and bottom kerf width. The best effective parameters in obtaining the
optimal cut were reported as the final results. Seon et al. [24] achieved the desired cut by
changing the process parameters in a laser cutting process. The process was performed on
stainless steel sheets. Among all studied parameters, increasing the cutting speed led to a
better performance among other parameters; also, the cutting quality was appropriate in this
case. Further, the quality of the cut was improved slightly with increasing the waiting time. In
addition, Shin et al. [25] used a 6 kW fiber laser to cut 100 mm thick pieces of stainless steel.
Examining the cutting quality and process parameters depicted that despite the use of a low

3
laser power, as compared to the previous studies [17], the cutting quality was suitable for
stainless steel and carbon steel parts. Therefore, there was a very good cutting ability when
compared to other known values; also, the maximum cutting speed for similar thicknesses
was more in comparison to other groups. Parthiban et al. [26] also investigated the effect of
parameters of CO2 laser cutting on a stainless steel sheet. Based on their results, the best
parameters for obtaining a suitable cut were introduced; these included laser power, gas
pressure and laser speed. They also reported that other parameters could affect the quality of
the cut.

By changing the laser cutting speed, Jarosz et al. [27] investigated the thermal effects and the
impact of the quality of the cutting surface on the AISI 316L stainless steel alloy. Their
results indicated that reducing the cutting speed increased the width of the HAZ; also, the
lower part of the cutting surface was damaged by further reducing the speed. Finally, the
optimal process speed was achieved to perform an ideal cut. In another laser cutting process
(CO2 and fiber), Librera et al. [28] examined the quality of the cut surface of stainless steel.
The evaluation criteria for them was the use of ISO 9013 standard; their results illustrated
that by changing the laser parameters, ideal surface roughness and cutting quality could be
achieved. Mullick et al. [29] also analyzed the effect of the underwater laser cutting
performance on the AISI 304 stainless steel sheet. Optimal parameters were introduced using
the response surface coating; the results confirmed the appropriate cutting quality. Also, the
use of pulsed cutting reduced the loss of laser scattering. Further, Pessoa et al. [30]
investigated the cutting surface of AISI 304 austenitic stainless steel in a laser cutting
process. Their results indicated that the use of the laser technology reduced fatigue strength.
It was also found that process optimization parameters could lead to an ideal cutting surface.
On the other hand, Pocorni et al. [31], in the fiber laser cutting process, studied the fluid
dynamics and morphology of the cutting surface. Their results implies that the front of the
stainless steel laser cutting process was covered under the moving liquid more quickly. It was
also found that the production of scattered hump reduced the quality of the cut. In a laser
cutting process of austenitic stainless steel, Pessoa et al. [32] also investigated the fatigue
behavior due to shear. The outcomes depicted that by increasing the thickness of the steel
sheet, a pronounced surface relief of the cut was produced, ultimately reducing the fatigue
strength. It was also found that using the optimum process parameters could increase fatigue
strength. In addition, Choubey et al. [33] investigated the change in the Nd: YAG laser
parameters upon applying the laser cutting process of stainless steel. Their results clarified

4
that for specified pulse energy, a higher speed of laser cutting with the optimal amount of
pulse duration increased the spot overlap and pressure of the assist gas. Furthermore, Stelzer
et al. [34] examined the effect of the cutting quality of fiber and CO2 laser beams on stainless
steel. Their results indicated that the cut kerfs were almost similar in terms of dimensions and
size, but they varied in quality and shape of the cut appearance.

2. Experimental Procedure

Commercial fiber laser cutting system with the maximum output power of 1200 W, model
(HS-GB-22Q), was used for the cutting experiments with the Raytools cutting head. Nitrogen
gas was passed through the co-axial conical nozzle with the average pressure in the range of
5-8 bars. Measurement of the temperature of the sheets adjacent area of the cutting region
was done during the experiments by using k-type thermocouples with the surface diameter of
1mm at the tip to monitor the temperature history at 1 mm distance from the center of the cut
kerf. The thermocouple data were recorded by Advantech USB4718 DAQ card and labview
software. The material was duplex stainless steel 2205 with 1mm thickness.

The laser cutting surface roughness was measured by surface roughness Perthometer Mahr
M2. The macroscopic images of the laser cut sections were taken by an Olympus SZ-X16
Stereoscope. A schematic diagram of the laser cutting setup is shown in Fig. 1.

Figure 1. Laser cutting experimental setup, a) schematic, b) actual view.

5
3. Design of the Experiments

Central composite design was then selected as a means of the experimental design useful in
the response surface methodology, to create a quadratic model for the response variables
without using a complete three-level factorial experiment to reduce the number of
experiments.

The Response Surface Methodology (RSM) was then applied to model and investigate the
effect of critical parameters on the desired responses. Central composite design was also
utilized to analyze the effect of the process parameters (cutting speed, laser power and focal
length) trend on the temperature and surface roughness of the cutting surface. The CCD
Design was designed using the Minitab software. Three parameters i.e laser power, cutting
speed and focal length were selected as the three variables. Generally, the experimental
design included 17 experiments; these consisted of 8 factorial points, 6 axial points and 3
cubic center experiments. Table 1 illustrates the factors lower and upper levels. The
experiments were designed at one block with random order for execution of the real
experiments tests in order to reduce possibilities of errors. The center point was repeated 3
times by considering the acceptable repeatability of the tests results. Table 2 shows the
process variables design matrix at five levels (from -2 to +2), as well as the responses
(temperature and cutting surface roughness).

Table 1. The factors levels selection

Factor Level (-2 , +2)
Welding Speed
3.5, 5
(mm/min)
Power
700, 1100
(W)
Focal
0.5, 1.25
(mm)

6
 Table 2. CCD design matrix of the experiments

Exp. No Welding Speed Power Focal Temp Ra

(mm/min) (W) (mm) (°C) (µm)
1 4 800 1 345 3.38
2 5 800 1 294 4.25
3 4.5 900 0.75 362 2.7
4 4 1000 1 375 1.16
5 5 1000 0.5 456 2.38
6 5.5 900 0.75 302 3.78
7 4.5 900 0.75 379 2.14
8 5 800 0.5 273 4.35
9 3.5 900 0.75 329 2.26
10 4.5 900 0.25 387 1.97
11 4 800 0.5 327 3.2
12 5 1000 1 406 3.3
13 4.5 900 0.75 385 2.38
14 4.5 900 1.25 351 3.41
15 4.5 700 0.75 258 4.61
16 4.5 1100 0.75 456 1.67
17 4 1000 0.5 411 1.85

4. Results and discussion

To investigate the effect of each parameter through the response surface, the analysis of
variance (ANOVA) method was performed to investigate the effectiveness of each factor on
the response surfaces; these factors included the surface roughness and temperature around
the cut kerf through.

The effect of each of the cutting parameters on the temperature around the cut kerf was then
determined using ANOVA, as shown in Table 3. According to the p-value < 0.05, the two
parameters of laser power and cutting speed had the greatest effect on the temperature around
the cut kerf. Among other terms, the interaction of the cutting speed and laser power led to a
significant effect on the temperature around the cut kerf. The values of Rsq of 95% and the
lack of fit equal to 0.75 indicated the acceptable curve fitting of the experimental data of the
model’s outputs.

7
 Table 3. The results of the Analysis of Variance for the temperature.
Source DF Adj SS Adj MS F-Value P-Value
Model 6 52137.3 8689.5 89.51 0.000
Linear 3 41817.2 13939.1 143.58 0.000
speed 1 430.6 430.6 4.43 0.061
power 1 40501.6 40501.6 417.18 0.000
focal length 1 885.1 885.1 9.12 0.013
Square 1 4271.8 4271.8 44.00 0.000
speed*speed 1 4271.8 4271.8 44.00 0.000
2-Way Interaction 2 6048.3 3024.1 31.15 0.000
speed*power 1 4095.1 4095.1 42.18 0.000
power*focal length 1 1953.1 1953.1 20.12 0.001
Error 10 970.8 97.1
Lack-of-Fit 8 686.2 85.8 0.60 0.750
Pure Error 2 284.7 142.3
Total 16 53108.1
S R-sq R- R-sq(pred)
sq(adj)
9.85314 98.17% 97.08% 95.39%

The regression equation obtained from the response surface methodology included linear,
square and nonlinear terms. Equation 1 shows the relationship between temperature and laser
cutting parameters of stainless steel (duplex). Table 4 also represents the ANOVA results and
their coefficients for the equation (1).

Temp = 338 + 53.5 speed - 1.064 power + 533 focal length - 52.35 speed*speed (1)
+ 0.4525 speed*power - 0.625 power*focal length

Table 4. The results of the Analysis of Variance for the equation (1).
Term Coef SE Coef T-Value P-Value VIF
Constant 370.91 3.03 122.56 0.000
speed -5.19 2.46 -2.11 0.061 1.00
power 50.31 2.46 20.42 0.000 1.00
focal length -7.44 2.46 -3.02 0.013 1.00

8
 speed*speed -13.09 1.97 -6.63 0.000 1.00
speed*power 22.63 3.48 6.49 0.000 1.00
power*focal length -15.62 3.48 -4.49 0.001 1.00

The response surface graph for different sets of the parameters clearly indicated the trend of
response variation according to the process parameters changes. Figure (2) shows that with
increasing the laser power from 700 to 1100 W, the temperature around the cut kerf was
raised from 180 to 500°C. On the other hand, with increasing the cutting speed, the
temperature of the cut kerf was decreased. This reduction rate was observed less at powers
higher than 700 W, which was due to the higher energy density of the applied laser beam per
unit time emitted to the workpiece.

Figure 2. Response surface graph of the temperature of the cut kerf for the cutting speed and laser
power.

Figure (3) shows the effect of cutting speed variation and focal length on the temperature of
the cut kerf. With increasing the focal length, the temperature was decreased; however, with
changes in the cutting speed at different focal lengths, due to the change in the maximum
temperature in the sheet thickness region, the read surface temperature was different. By
increasing the cutting speed from 4 to 5.6 m/min, the temperature was decreased about 50°C.
Compared to the cutting speed and laser power, focal length changes did not show any
significant changes in temperature variations around the cut kerf.

9
 Figure 3. Response surface graph of the temperature of the cut kerf for the cutting speed and focal
length.

Figure (4) shows that the maximum temperature change around the cut kerf at a focal length
of 0.4 mm was due to the changes in the laser power. At the focal length of 0.4 mm, the
temperature changed about two folds (200°C), as compared to the focal length of 1.2 mm.
Therefore, it could be said that the laser power had the greatest effect on the temperature
changes around the cut kerf and cutting at the distance near the focal point, which was more
sensitive to temperature variation by changing the laser beam line energy.

Figure 4. Response surface graph of the temperature of the cut kerf for the laser power and focal
length.

10
Table 5 illustrates the ANOVA results for the surface roughness of the cutting surface. It
could be evidently observed that the laser power and cutting speed had a notable effect on the
cutting surface surface roughness. Due to having a p-value <0.05, a value of Rsq = 86% and a
lack of the fit value of 0.25, the data obtained from the ANOVA analysis were in a good
agreement with the experimental results.

Table 5. The results of the Analysis of Variance for surface roughness.

Source DF Adj SS Adj MS F-Value P-Value
Model 6 14.1682 2.36137 10.47 0.001
Linear 3 13.9341 4.64471 20.59 0.000
speed 1 3.7346 3.73456 16.55 0.002
power 1 9.5636 9.56356 42.39 0.000
focal length 1 0.6360 0.63601 2.82 0.124
Square 1 0.1785 0.17850 0.79 0.395
speed*speed 1 0.1785 0.17850 0.79 0.395
2-Way Interaction 2 0.0556 0.02781 0.12 0.885
speed*power 1 0.0528 0.05281 0.23 0.639

power*focal length 1 0.0028 0.00281 0.01 0.913

Error 10 2.2564 0.22564

Lack-of-Fit 8 2.0985 0.26231 3.32 0.252
Pure Error 2 0.1579 0.07893
Total 16 16.4246
S R-sq R-sq(adj) Rsq(pred)
0.475011 86.26% 78.02% 56.50%

The regression equation of surface roughness including linear, square and nonlinear terms is
shown in equation (2), representing the relationship between surface roughness and laser
cutting parameters. The ANOVA results and their coded coefficients for the equation (2) can
be observed in Table 6.

Ra = 18.7 - 3.54 speed - 0.0156 power + 0.12 focal length + 0.338 speed*speed (2)
+ 0.00163 speed*power + 0.00075 power*focal length

11
 Table 6. The results of the Analysis of Variance for the equation (2).
Term Coef SE Coef T-Value P-Value VIF
Constant 2.790 0.146 19.13 0.000
speed 0.483 0.119 4.07 0.002 1.00
power -0.773 0.119 -6.51 0.000 1.00
focal length 0.199 0.119 1.68 0.124 1.00
speed*speed 0.0846 0.0951 0.89 0.395 1.00
speed*power 0.081 0.168 0.48 0.639 1.00
power*focal length 0.019 0.168 0.11 0.913 1.00

As shown in Figure (5), with increasing the laser power, the surface roughness was somewhat
decreased. On the other hand, at first, raising the cutting speed reduced the roughness and
then increased it. So, increasing the cutting speed from 4 to 5.6 m/min, the surface roughness
was raised due to the decrease of the temperature and also, bigger cutting lines. Because
changes in the laser power rate and cutting speed had effects similar to roughness changes,
the surface shape had almost linear changes.

Figure 5. Response surface graph of the surface roughness of the cutting surface for the
cutting speed and laser power.

Figure (6) shows that by raising the cutting speed at different focal lengths, the surface
roughness rate was increased further. With increasing the focal length, the roughness of the
cutting surface surface was enhanced due to the decrease of temperature and the formation of

12
more dross attachment. At the laser cutting speed of 4m/min and the focal length of 0.4mm,
the lowest roughness was created. It, thus, showed that decreasing the temperature could
increase the surface roughness. Also, increasing the cutting speed could naturally enhance the
surface roughness by changing the pattern of striations.

Figure 6. Response surface graph of the surface roughness of the cutting surface for the cutting speed
and focal length.

At the designed levels of the experiments, increasing the laser power continually diminished
the surface roughness. Increase of laser power and therefore, the rise of the laser line energy
not only boosted the temperature, but also could reduce surface roughness at the appropriate
temperature gradient. Excessive temperature gradient could harm the roughness of the cutting
surface. As could be observed in Figure (7), by increasing the laser power, the surface
roughness was continuously decreased. The highest reduction rate of surface roughness was
at the focal length of 0.4 mm, at which the laser energy density was at the highest level. The
trend of roughness changes according to the variation of laser power and focal length was
almost linear.

13
 Figure 7. Response surface graph of the surface roughness of the cutting surface for the focal length
and laser power.

Variation of laser welding processing parameters clearly changes the condition predominated
the temperature of the cutting region. Therefore, the temperature field indirectly determines
the cut surface quality due to having melting and exiting of the molten metal. The shape and
topography of the cut surfaces can be correlated with temperature field changes so as to
indirectly assess the cut surface quality.

Figure 8 depicts the effect of the cutting speed on the quality of the cutting surface through
the visual analysis of the striation patterns. As can be seen, at the cutting speed (4m/min),
because of the excessive temperature rise, in comparison to the higher cutting speeds, some
cavities on the cutting surface could be observed. Therefore, the surface roughness was
increased at the low cutting speed. By increasing the cutting speed, the striation pattern
became finer, thereby reducing the roughness clearly (see figure 8b). Further increase of the
cutting speed to 5.6 m/min clearly changed the striation pattern angle at the threshold level,
thus indicating the sheet thickness (figure 8c). At this condition, the cutting surface roughness
was relatively increased due to the lower laser beam interaction time and the lower
temperature at the lower part of the cut kerf region. Hence, the striation pattern angle was
changed from the straight line.

14
 Figure 8. Effect of cutting speed at striation pattern for a) 4m/min, b) 4.8m/min, c) 5.6m/min.

Figure 9 illustrates the effect of increasing the laser power on the striation pattern changes. It
could be vividly observed that the laser power played a crucial role in determining the
volume of melting at the cut kerf region. As can be seen in figure 8a, due to having a low
laser power, the penetration melt ratio was clearly lower and a threshold layer could be
observed at this region. Therefore, uncomplete melting was observed at the low part of the
cut kerf. Increase of the laser power up to 900w evidently improved the melting condition
and penetration along the cut thickness (figure 9b). Increasing the laser power up to 1100W,
while reducing the average results of surface roughness, led to the observation of some
cavities and dross at the bottom cutting surface (figure 9c). It could be, therefore, said that
with the accumulation of the melt volume and high laser beam energy in the bottom region of
the cut kerf area, cutting could induce such defects.

15
 Figure 9. Effect of laser power at striation pattern for a) 700W, b) 900W, c) 1100W.

5. Conclusion

The effect of the process parameters on the temperature and cut surface quality was
analyzed through the CCD design of experiments and response surface methodology.
 The laser power and cutting speed had a significant effect on the temperature
variation around the cut kerf through regularly changing the laser energy density and
laser line energy at the time unit.
 The temperature around the cut kerf was raised from 180 to 500°C by increasing the
laser power from 700 to 1100 W. So, there was a linear relation between laser power
and temperature field in the cutting region.
 By increasing the cutting speed from 4 to 5.6 m/min, the temperature was decreased
about 50°C; also, the temperature of the cut kerf was decreased and the time of heat

16
 dissipation to the adjacent areas significantly decreased. It clearly reduces the burning
and heat accumulation to prevent overheating region.
 Laser power and cutting speed had a notable effect on the cutting surface surface
roughness. Raising the cutting speed naturally increased the surface roughness by
changing the pattern of striations from strait to the inclined angle at the sheet
thickness.
 Increasing the laser power continuously decreased the surface roughness. The highest
rate was at the focal length of 0.5 mm, at which the laser energy density was at the
highest level of 5100w/mm2.
 Increasing the cutting speed made the striation pattern rougher, thereby increased the
roughness clearly about 10 percent.
 At the laser power of 900W, the melting condition and laser beam penetration were
evidently improved along the cut thickness.

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