How Waterjet Cutting Makes a Difference in Aerospace

Industrial waterjet cutting is an extremely versatile manufacturing technique, useful in a wide variety of industries, and Hydro-Lazer is proud to be part of that legacy. One particularly noteworthy field of waterjet machining is the aerospace industry, a field which has exacting demands for the quality and precision of its parts. The range of materials and parts that are produced with the help of waterjet cutting is quite extensive: aircraft engine and body parts, military solutions like missile components, and even parts essential to space vehicles.

Waterjet cutting and machining has been a key part of the aerospace industries for almost half a century, due in no small part to how accurate it is. Short of a laser, there’s not much that is more precise than a waterjet cutter, and nothing as clean.

What kinds of materials are worked by waterjet cutting for aerospace purposes? Just about anything you could imagine: Aluminum, glass, foam, plastic, rubber, copper, carbon fiber and even titanium and metal alloys. On top of its cutting abilities, waterjet machining is environmentally friendly, producing no hazardous gasses or debris, and allowing raw materials to be preserved and reused.

Hydro-Lazer has been part of aerospace engineering and manufacturing with its waterjet machining, and if you find that you have need of waterjet aerospace, we are happy to help. Please contact us for quotes, or for any information on our capabilities and what we can offer you.

History of Waterjet Cutting

Waterjet cutting technique uses a high pressure stream of water to cut different materials. The early usage dates back to Roman Empire, who used it for hydraulic mining and land development. In the early 1930’s, a Paper Patent Company used relatively low pressure water for cutting soft metals. The first reliable ultra-high pressure pump was developed in 1970 by OMAX Corporation. In this blog, we will discuss the evolution of Waterjet cutting process till date.

Evolution of Waterjet Cutting:

The early waterjets only managed to cut soft materials. However, the modern waterjet machines use garnet abrasive, which are capable of cutting hard materials like steel, stone, and glass.

  • 1930’s: Waterjet devices were used were used to cut, meter, and reel paper by engaging a low pressure water on the surface of the seasoned metals.

 

  • 1940’s: By this time, advanced high pressure water jet machines started gaining popularity. These machines were specifically developed for aviation & automotive hydraulics.

 

  • 1950’s: Liquid jet machines in the pressure range of (100000 PSI, 6900 bar) were used to cut plastic and aerospace metals. The first liquid jet machine was developed by John Parsons.

 

  • 1960’s: Ultra high pressure hydro jet machines up to 50,000(3,450 bar) were used to cut metal and stone. They were also used in polyethylene industry.

 

  • 1970’s: The first commercial waterjet cutting system developed by Bendix Corporation was introduced in the market.

 

  • 1980’s: First abrasive waterjet nozzles ROCTEC ceramic tungsten carbide composite mixing tubes were developed by Boride Corp. These nozzles were made from a patented carbide material.

 

  • 1990’s: OMAX Corporation developed patented ‘Motion Control Systems’. It was also used to locate the waterjet stream.

 

  • 2000’s: The introduction of zero tapper waterjet improved the precision cutting of parts with square, taper-free edges, including interlocking pieces and dove tail fittings.

 

  • 2010’s: The technology in 6 axis machines greatly improved the credibility of Waterjet cutting tools.

Throughout the history of Waterjet cutting, technology has evolved, became more reliable, more accurate, and much faster. If you are looking for a reliable waterjet cutting for your next project, you can always consider industry expert like Hydro-Lazer. The company always tries to find innovative ways to improve the process. For more information on waterjet cutting services, please click here.

7 Major Differences between Waterjet Cutting & Laser Cutting

Waterjet cutting and laser cutting are two of the most widely used techniques. Which one is the best among these? Well, both the cutting processes can get a good job done for you. However there are certain factors that decide which cutting process is suitable for what applications. In this post, will discuss some of these factors.

Difference between Waterjet Cutting and Laser Cutting

There are a number of differences in the two cutting processes. Here are a few major differences between waterjet cutting and laser cutting. These differences will help you choose the right cutting process:

  1. Definitions: As the name suggests, waterjet cutting is a process which uses water and an abrasive to cut different types of materials. In laser cutting, a high intensity beam is used to cut through the metal.
  1. Edge Finish: Laser cutting process produces heat. This heat creates a Heat Affected Zone (HAZ). This HAZ needs a secondary finish based on the requirements. On the other hand, waterjet cutting process does not create HAZ. Thus, it does not distort the parts. Besides this, unlike laser, waterjet delivers a smooth edge finish. This eliminates the need for secondary finishing process.
  1. Thickness of the Material: With the help of a waterjet machine, you can cut materials up to 3 inches thick. On the other hand, lasers can cut parts up to 0.25 inch, and metals of thickness around 11/2 inches.
  1. Accuracy: As far as the accuracy of cutting is concerned, laser has tolerances close to +/-.002”, whereas waterjet has tolerances as close as +/- .003”. Another factor that plays an important role in deciding which cutting process is ideal for what application, is part features. Holes that have their diameter smaller than the material’s thickness require waterjet cutting, and cannot be cut using laser. Also, waterjet cutting can be used to cut small holes in thick materials.
  1. Material: Lasers have the capability to cut through various types of materials other than metals. When laser cutting is done on materials such as rubbers and plastics, they produce byproducts. On the other hand, when these materials are cut using waterjet, there no harmful byproducts are produced. Lasers find it hard to cut materials like copper and aluminum, which are highly reflective. Though the cutting speeds of laser and waterjet are almost same, the edge quality is considerably better in case of a waterjet cutter.
  1. Cutting Speed: When the material thickness is less than 1 inch, waterjet machines can cut five to ten times faster compared to Electrical Discharge Machines (EDM). For non-reflective and thin materials, the cutting speed of lasers is very high. For example, consider a carbon steel material of thickness 1 inch. A waterjet, which is equipped with 0.030 inch nozzle, can cut the material at 2.9 IPM. On the other hand, a laser that is equipped with a 3,800-W resonator and a 2-mm coaxial nozzle, has the capability of cutting the material eight times faster as compared to waterjet.
  1. Surface Cutting: Waterjet cutting works better for flat surfaces, however, laser cutting works for squares, tubes, flat sheets, bars, and other surfaces as well.

Each type of cutting has its own advantages and disadvantages. However, usually garnet is used as an abrasive material in waterjet cutting. Garnet being a biologically inert material, does not emit any noxious fumes, thus possesses no hazard of fires. If you are unable to make up your mind, you can always talk to an industry expert like Hydro Lazer – a leading service provider of waterjet cutting and has two decades of experience in the field. For more queries related to waterjet cutting, please feel free to reach out to us.

Everything You Need to Know About Waterjet Floor Inlays

Flooring is one of the most important elements of a structure. However, that is not enough, you may be specific about their look and feel too.  If you are very particular about the aesthetics of the place, you should consider inlays, which are designed to accentuate the beauty of the flooring. These are decorated flooring patterns that are cut out of the flooring material. These patterns are created using various methods. However, today manufacturers are largely using waterjet cutting to produce attractive flooring inlays. Why? Read the post below to know the answers.

Linoleum Floor Tiles

Why is Waterjet Cutting an Ideal Method for Creating Floor Inlays?

Waterjet cutting, also known as hydro jet cutting is perfect for creating flooring inlays due to the following reasons:

  • Cutout Accuracy: Waterjet machines provide high cutting accuracy. Hence, it is perfect for creating inlays that require high precision, as well as tolerance.
  • Design Flexibility: Waterjet machines produce a sharp water stream, which can cut through any type of material, and allow design flexibility. Hence, flooring inlays can be created in any desired shape. Designers can also create intricate detailing on these inlays.
  • Minimal Cutting Defects: Waterjet cutting receives its name from a water stream that is used to cut surfaces. Thus, it is a cold cutting process, which produces no heat. This minimizes the chances of surface deformation due to heat distortion.
  • Superior Edges: Water jet cutting is the only method that can ensure burr-free edges, which is why it is becoming a choice for creating tile inlays. Most times the inlay patterns require no secondary finishing.

 

Porcelain tile

Porcelain tile with waterjet cutting

Introduction to Types of Waterjet Flooring Inlay Types

There is an abundance of variety when it comes to creating waterjet flooring inlays. Here, we have attempted to differentiate these inlays on the basis of flooring materials, as well as flooring patterns.

Flooring Inlay Types Based on Flooring Materials

Following are some of the popular types of flooring inlay materials:

  • Porcelain Tiles: These tiles are made from ceramic, and used to cover walls or floors.
  • Rubber Floor Tiles: These tiles are ideal for high traffic environment.
  • Laminated Floors: Generally, hardwood flooring is laminated to protect from scratches, dulling, stains, etc.
  • Linoleum Tiles: These are the types of eco-friendly flooring created using wood flour, as well as eco-friendly materials. These tiles can be availed in different styles, as well as colors.
  • Vinyl Composition Tiles: These tiles are scratch resistant, water resistant, and built for high traffic areas. These tiles require no maintenance, and are becoming a choice for homeowners. Various expensive inlay patterns can be experimented over the vinyl composite tiles using waterjet machine. This allows users to enjoy the benefits of expensive patterns of hardwood, oak, and ceramic tiles at low costs.
  • Slate Tiles: These tiles are perfect for any room in the home, and can improve aesthetics of any place.
  • Fritz Tiles: These tile inlays are perfect for high-traffic areas, where longevity, appearance, and low-maintenance becomes essential requirements. Custom logos or designs can be created over fritz tiles using waterjet machines.
  • Carpets: These flooring materials have been around for a long time. Earlier people were only aware of plain bright carpets. Thanks to waterjet cutting, today colorful designer carpets with various designs are getting popular.

Flooring Inlay Types Based on Flooring Patterns

Following are some of the popular waterjet flooring inlays based on patterns:

  • Medallions: The medallions are large circular accent pieces that are cut from the material such as natural stone, slate, granite, porcelain, limestone, etc. Waterjet cutting is a suitable method for creating inlays because they help materials retain their original properties. Stone medallions and wooden medallions are two of the most popular waterjet inlays used around the world.
  • Waterjet stone medallions are created by cutting large stone slabs by tightly assembling on a backer. Stones are polished and sealed to ensure there are no gaps between pieces. These stones are cut to tight tolerances using a waterjet machine. Also, stone medallions require less maintenance and are engineered to fit into hardwood or stone floors.
  • Parquet: This is a classic flooring pattern created by joining wooden pieces in a decorative manner. Parquet patterns are created in various angles, as well as geometric patterns- triangles, lozenges, squares, etc. These patterns are glued over concrete or wood installations. Following are the two popular types of parquetry flooring styles:
  • Herringbone: This pattern features parallelogram or rectangular shaped wooden inlays arranged in zigzag patterns to resemble bones of herring fish. French Herringbone, also known as Chevron Herringbone refers to rectangular wooden boards that are cut at 45-degree angles. Double herringbone boards are created in three sizes.
  • Marquetry: These patterns are created by arranging veneer pieces in particular designs to create decorative flooring. Custom marquetry inlays are used over wall panels, cabinetry, door ornaments, etc. The marquetry pieces are custom created, and can be lacquered or sealed or offered unfinished. 
  • Floor Borders: Waterjet cutting is used to create customized patterns. The pre-assembled patterns can be glued to any clean, dry, and sub-floor.
  • Accent Floor Tiles:  These floor types are used to accentuate tile arrangements in bathrooms, kitchens, or other recreational areas. Decorative patterns are created over the floor tiles using a waterjet cutter.

Apart from the above-mentioned inlay types, you can experiment different types of decorative and designer flooring by employing water jet cutting. By now you might have realized that sky is the limit of imagination when it comes to creating inlays from waterjet cutting. You don’t need to bother about the material, heat, or temperature restrictions when working with waterjet cutters because they use sharp water stream to cut through surfaces.

Merry Christmas & Happy New Year 2017

New Year

Christmas is here, and so is the New Year 2017. This is the perfect time to thank and wish each and every one of those who have been associated with Hydro-Lazer. It has been a great year to work with you all. Your continuous support and feedback has helped us improve in terms of products and services. Here is to all of you – Merry Christmas! Cheers!New Year is just round the corner. We all are about to enter 2017. We hope this New Year brings lots of happiness and prosperity to all of us. We hope to strengthen the business bond we share with our valuable customers.

We have made a lot of customers happy this year, and we are all set to make even a greater number of our customers satisfied and happy with our products and services the next year too. We hope you all have a great celebration on Christmas. Here is team Hydro-Lazer wishing all our stakeholders, customers, and clients a Happy and Prosperous New Year 2017!

How do Waterjet Cutting Machines Create Industrial Components?

Waterjet cutting has become one of the popular manufacturing methods used by organizations in different industries. At Hydro-Lazer, we get a lot of enquiries from first-time customers regarding their component manufacturing requirements. However, many customers are under the impression that only a stream of high pressure water is required to perform the cutting process. The fact is, there are different components involved in the waterjet cutting process. As we get many enquiries like the example given above, we decided to put up a post that will help explain the components to new customers.

Understanding the Operation of Waterjet Cutting Machines through its Components

The following points will help understand the different component used with or in waterjet cutting machines, and their significance.

  • CAD Program: Waterjet machines are computer controlled equipment. They require a component design as well as exact specifications to create the part. Most waterjet cutting organizations utilize Computer Aided Design (CAD) programs to create a 3D version of the part. This 3D drawing of the part is programmed into the waterjet machine via computer.

 

  • System Controller: The waterjet cutting head is controlled by a computer, as it is extremely complicated to control the head, and ensure that the right speed and pressure is used to cut the desired part out of the material. CNC computers are used to make the movement of the cutting head simpler. The specifications and required calculations are entered into the computer, the operator presses ‘print’, and the waterjet cutting machine begins creating the desired component.

 

  •  Pressurized Pumps: Heavy duty pumps are used with waterjet cutting machines to produce a water stream of immense pressure. The pumps allow the operator to manipulate the water in terms of pressure, speed, and intensity. Organizations utilize pressurized pumps for low, as well as high pressure waterjet cutting machines.

 

  • Cutting Heads: Waterjet machines utilize specialized cutting heads comprising ruby or diamond orifices. Head moves along the material to cut and create the component design. Generally, the orifice is aligned with the abrasive nozzle to ensure quality cutting performance. Some cutting heads are designed to cut the material from an angle. This allows the waterjet machine to create components with complex designs and specifications. The use of the cutting head also allows the machine to achieve tight tolerances.

 

  • Abrasive Nozzle: As the name suggests, the abrasive waterjet nozzle is the faucet through which the cutting abrasive is released along with the water. The combination of the high pressure water, abrasives, and the cutting head allows the machine to cut through practically any material quickly and efficiently.

 

  • Water Tank: A specialized water-filled tank is attached to the waterjet machine. Its primary function is to help dissipate the energy that gets created after the machine has cut into the material, and the cutting head is changing its position.

 

  • Abrasive Hopper: This product is used depending on the kinds of projects that manufacturer takes up. If the manufacturer focuses on large projects, then a large amount of abrasive will be required. The abrasive hopper is used to store the excess unused abrasive. The abrasive is passed through the hopper to the machine to replace the old abrasive, as and when each manufacturing cycle is completed.

 By understanding the above information, customers will be in a better position to make clear inquiries regarding their manufacturing requirements. We at Hydro-Lazer are always willing to clear doubts and answer any questions you may have. For more information, feel free to contact us.

5 Reasons Why Waterjet Cutting is a Better Method for Tile Inlays

Waterjet cutting is one of the most preferred methods for tile inlays because it offers immense creative freedom over any flooring material. The waterjet cutting creates straight cuts, curves, lettering, intricate floor designs, and internal holes. This post explores why waterjet cutting is a better method for the tile inlay.

Benefits of Waterjet Flooring Inlays

Compared to other traditional cutting tools, waterjet cutting reduces process time for tile inlays. Below mentioned are five benefits of waterjet flooring inlays.

  1. Accurate internal cutouts: Waterjet cutting offers high cutting accuracy of ±0.1 to ±0.2mm. Thus, it is preferred for custom tile cutting in industries which require high accuracy and tight tolerance. Waterjet cutting helps the flooring material to retain its strength and visual appearance.
  2. Cuts virtually any shape: Waterjet machines produce a sharp cutting stream, which can be used to create any shape. This allows users to create custom floor inlays in any shape and size.
  3. Reduces cutting defects: Waterjet cutting is a cold cutting process, which means no heat is produced. Thus, there is no chance of deformation due to heat distortion. This is advantageous for flooring materials that require additional machining and cutting. No dust or toxic fumes are produced in the process.
  4. Offers superior edge quality: Waterjet cutting offers superior, burr-free edges, which is one of the reasons why it is recommended for tile inlay cutting. Abrasive flow rates, controlled pressure, nozzle size, and speed ensure superior edge quality. Many times, waterjet cut tiles don’t need secondary finishing or additional edge treatment, thus offering significant savings of time and money.
  5. Improves Operating Efficiency: Waterjet cutting eliminates any need for tool changes during the cutting or tile inlay process. The same tool is used for cutting a tile and creating intricate designs.

Waterjet tile inlays are used at memorials, monuments, kitchen, and bathroom vanity tops, etc. The above benefits will help you in making your decision about selecting waterjet cutting for your tile inlay project.

Why to Choose Laminate Flooring Inlays with Waterjet Cutting

Laminate flooring is a popular type of flooring, which imitates texture of real wood and stone. Laminate flooring inlays refer to any kind of logos, emblems, designs, and customized decorative patterns set into the flooring. The quality of laminated inlays will depend on the cutting method. This post explores why water-jet cutting is the ideal perfect method for creating high quality laminated floor inlays.

How Water-jet Cutting Contributes to Quality Laminated Flooring Inlays?

Water jet cutting or hydro cutting is employed for creating floor inlays for laminated flooring due to the following reasons.

  • No Heat Affected Zones: As waterjet cutting is an automated process, where the high pressure water stream is directed to the cutting material. This means no heat is produced during the process. This results in burr-free inlays with perfectly cut edge.
  • Fast: Waterjet cutting is a fast, accurate and flexible process. It enables the user to have high speed and control over the cutting process.
  • Cost-Effective: Water jet cutting is a self a sufficient system, and does not require any additional tooling. This reduces the overall cost assumed by the customers.
  • Versatility: Hydro cutting can be used to cut various materials including laminates, vinyl, rubber, marble, etc.

Benefits of Laminated Flooring Inlays Produced by Water Jet Cutting
Waterjet cut inlays for laminated flooring have many advantages over other types of flooring inlays due to the following reasons.

  • Clean: The waterjet machine produces no toxic gases or fumes, while cutting the flooring inlays because there is no burning involved. Also, water jet cutting doesn’t impair the strength and original constitution of the material.
  •  Innovative: Hydro cutting is an excellent process over laser or flame cutting processes because it allows cutting flexibility. Hence, the inlays are clean-cut, attractive, and durable.
  •  Advanced Cutting Process: Hydro laser cutting is controlled by several automated processes. This helps speed up the process, while making it easy and simple with precise results every time. The above-mentioned points confirm that water jet cutting can contribute to the beauty and elegance of laminated flooring inlays. You can always seek the assistance from a professional water jet cutting services to get your inlays done properly.

Create Accurately Cut, Incredible Laminate Floor Designs with Water Jet Cutting

Waterjet cutting utilizes a high pressure jet of water to cut different kinds of materials. This is one of the most innovative green technology alternatives for traditional cutting methods. Today, this advanced waterjet cutting process is used to design laminated flooring for residential, as well as commercial facilities.

Major Benefits of Waterjet Cutting

The major benefits of using waterjet cutting to create laminate floor inlays include:

  • Eco-Friendly and Economical: Waterjet cutting is an economical and eco-friendly technology. The process does not leave behind any hazardous waste, and thus reduces the cost required for waste disposal. Also, the water used during the process can be recycled through filtration, and reused for future hydro cutting assignments.
  • Non-Toxic and Natural: Non-toxic abrasive grains are combined with the high pressure water just before it leaves the nozzle. The combination of high velocity waterjet and fine abrasive grain particles ensure easy material cutting. Also, it doesn’t produce any heat, hence the possibility of melting of material is completely negated.
  • Highly Precise and Controlled: The hydro cutting process is computer programmed and controlled. The process is precisely designed to ensure maximum material usage and minimal wastage. The high pressure waterjet cuts the material with maximum accuracy, as close as ± 0.03 mm. Usually, CAD/CAM software is used to create beautiful inlay floor designs.

List of Ancillary Benefits

Additional benefits of the advanced waterjet cutting process have been listed below:

  • No wastage
  • Incredible speed
  • Short setup times
  • No heat generation
  • Incredible precision
  • No fixtures required
  • Excellent edge quality
  • No re-cutting required
  • Only one tool required
  • Safer work environment
  • No need to change the tool
  • Cuts the material in 2D shape

Waterjet cutting is the most advanced cutting process, which offers incredible benefits at affordable prices. If you have a design in mind for your home or office, contact Hydro-Lazer today.

Why Waterjet Systems are Perfect to Provide Metal Cutting Services

Components for mechanical systems are constructed from various metals. These include stainless steel, aluminum, and titanium. The construction needs to be absolutely precise to ensure that the new component can be easily installed in an existing system. It should also perform as well as the original component. For precise component manufacturing, you need a precise cutting system. Waterjet metal cutting is the ideal solution for this requirement.

Reasons to Choose Metal Cutting with Waterjet Machines

There are a variety of beneficial reasons why waterjet cutting is the perfect solution to create metallic industrial components.

  • Versatility: Compared to laser cutting machines, waterjet cutting is extremely versatile. It can be used to cut extremely thick metals like titanium. Waterjet systems have the capability to cut the metal in thicknesses up to 305 mm. Such thicknesses cannot be achieved with laser cutting without deforming the metal.
  • Affordability: One of the reasons why laser cutting systems are not chosen by organizations is that they are extremely expensive. Prices of new laser machines start from $350,000. However, waterjet cutting is more cost-effective, with low cost machines starting from $40,000. The prices of large, high range machines can increase up to $100,000.
  • Material Deformation: Laser systems utilize intense heat to cut metals. However, the heat can also cause the metal to burr. Also, when the material cools down, the metal can harden along the edge of the cut. Waterjet metal cutting machines utilize cold water, and an abrasive additive to cut through the material. The lack of heat ensures that there is no change to the metal structure, or any deformation along the edge of the cut.
  • Speed and Precision: While laser systems are known for their speed, looking at the previous point, precision may not be up to the mark. Waterjet cutting machines have the ability to cut a design into the metal in a very short period of time. Creating perfect circular holes in metals is performed very easily.

All these various points prove that waterjet cutting is the most excellent metal cutting service to opt for. It is the perfect system to create high performance metal components.