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<p>This study experimentally investigates the CO₂ laser cutting characteristics of AA6061-T6 aluminium alloy with the aim of identifying and optimizing critical process parameters affecting cut quality. Owing to the alloy’s high infrared reflectivity and thermal conductivity, achieving consistent and high-quality cuts remains challenging, necessitating a systematic analysis. A Box–Behnken design based on Response Surface Methodology (RSM) was employed to evaluate the effects of laser power, cutting speed, assist gas pressure, and focal position on top and bottom kerf width, kerf taper, and surface roughness. A total of twenty-seven experiments were conducted for both straight and curved cutting profiles to assess geometry-dependent behavior. The results revealed that focal position exerted the most significant influence on all quality characteristics, followed by laser power, while cutting speed and gas pressure showed comparatively minor effects. Curved profiles demonstrated narrower kerf widths and improved surface finish, attributed to more effective molten material evacuation. The developed regression models exhibited high predictive capability, with prediction errors below 2%. The optimized process parameters derived from this study offer practical guidance for precision laser cutting of aluminium alloy components.</p>

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CO₂ Laser Cutting Behaviour of AA6061-T6 Aluminium Alloy Experimental Study and RSM-Based Process Optimization

  • 期刊论文

  • 发表日期：

    2026年3月24日

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  • Nitin A. Kharche,
  • Vishal N. Sulakhe,
  • Prasad.R. Baviskar,
  • Kiran Kaware

摘要

This study experimentally investigates the CO₂ laser cutting characteristics of AA6061-T6 aluminium alloy with the aim of identifying and optimizing critical process parameters affecting cut quality. Owing to the alloy’s high infrared reflectivity and thermal conductivity, achieving consistent and high-quality cuts remains challenging, necessitating a systematic analysis. A Box–Behnken design based on Response Surface Methodology (RSM) was employed to evaluate the effects of laser power, cutting speed, assist gas pressure, and focal position on top and bottom kerf width, kerf taper, and surface roughness. A total of twenty-seven experiments were conducted for both straight and curved cutting profiles to assess geometry-dependent behavior. The results revealed that focal position exerted the most significant influence on all quality characteristics, followed by laser power, while cutting speed and gas pressure showed comparatively minor effects. Curved profiles demonstrated narrower kerf widths and improved surface finish, attributed to more effective molten material evacuation. The developed regression models exhibited high predictive capability, with prediction errors below 2%. The optimized process parameters derived from this study offer practical guidance for precision laser cutting of aluminium alloy components.