Waterjet cutting at the aerospace industry
Waterjet cutting is widely used for a number of applications in the aerospace industry, as the method offers one distinct advantage for the cutting of metal: the material is not heated in the process and thus retains its original properties. As waterjet cutting is a cold cutting method, it does not cause stress in the metal or changes to the structure of the material. Waterjet cutting is therefore the preferred method in the production of fuselages made in titanium, motor parts from aluminium or titanium, fuselage parts in aluminium and cabin panelling elements.
The table below shows a comparison of laser, plasma and waterjet cutting and the respective material and processing characteristics. Each method has certain advantages and disadvantages, depending on the material to be cut.
Comparison of cutting methods
| |
Laser |
Plasma |
Waterjet |
|
Warping / deformation |
yes |
yes |
no |
|
Material hardening |
yes |
yes |
no |
|
Burr formation |
yes |
yes |
minimal |
|
Need for reworking |
yes |
yes |
minimal |
|
Loss of material |
hoch |
yes |
minimal |
|
Tolerances |
0,1 mm |
0,2–0,5 mm |
0,1–0,3 mm |
|
Hazardous vapours |
yes |
yes |
no |
|
Multilayer cutting |
no |
no |
yes |
|
Material thickness |
< 25 mm |
< 30 mm |
> 250 mm |
|
Non.metallic materials |
no |
no |
yes |
|
Multi-head application |
no |
— |
yes |
|
Composites |
no |
no |
yes |
Main advantages of waterjet cutting for the aerospace industry:
- No heat affected zones
- Stress-free cutting
- No damage to the metal structure
- Maximum flexibility as regards production processes
Cutting speeds
|
Abrasive flow rate |
350g/min |
|
Abrasive |
80 Mesh |
|
Quality of cutting edge |
fine - medium |
|
Orifice diameter |
0,25 mm |
|
Focussing tube diameter |
0,76 mm |
|
Pump pressure |
6.200 bar |
|
Material |
Thickness |
Cutting speed |
|
Steel |
20 mm |
50 mm / min |
|
|
|
|
Pump pressure |
4.200 bar |
|
Material |
Thickness |
Cutting speed |
|
Steel |
20 mm |
35 mm / min |
|
Steel |
10 mm |
120 mm / min |
|
Steel |
5 mm |
200 mm / min |
|
Titanium |
20 mm |
30 mm / min |
|
Titanium |
10 mm |
90 mm / min |
|
Titanium |
5 mm |
140 mm / min |
|
Aluminium |
20 mm |
75 mm / min |
|
Aluminium |
10 mm |
200 mm / min |
|
Aluminium |
5 mm |
350 mm / min |
KMT products for waterjet cutting at the aerospace industry
High pressure pumps
KMT Waterjet Systems offers a range of high pressure pumps that cater for all applications. They cover everything from maximum cutting waterjet pressures of up to 6200 bar to maximum volumetric flows of more than 15 l/min and simultaneous operation of a large number of cutting heads.
- STREAMLINE 60/125 PRO – waterjet cutting with 6200 bar
- STREAMLINE SL-V 15-100
- STREAMLINE SL-V 30/50 Classic
- STREAMLINE SL-V 150/200
Cutting heads for abrasive and pure water cutting:
- ACTIVE AUTOLINE PRO – abrasive cutting head for 6200 bar
- ACTIVE IDE PRO – compact abrasive waterjet cutting head for 6200 bar
- AQUALINE PRO – pure water cutting head for 6.200 bar
- ACTIVE AUTOLINE II – modular abrasive waterjet cutting head for 4100 bar
- ACTIVE IDE II – compact abrasive waterjet cutting head for 4100 bar
- AQUALINE – reliable pure water cutting head
Abrasive systems for abrasive waterjet cutting
- AMS III – abrasive management system consisting of an ABRALINE III abrasive bulk transfer system, a FEEDLINE IV metering system and ACTIVE AUTOLINE II or ACTIVE IDE II cutting heads
- ABRALINE III abrasive bulk transfer system
- FEEDLINE IV – abrasive metering system
About KMT Waterjet Systems
KMT Waterjet Systems is a leading multinational manufacturer of waterjet cutting systems. The company develops complete solutions for a wide range of industries and applications. Since 1971 the company has been dedicated to long-term customer relationships. Continuous investment in innovation has made KMT Waterjet Systems the market leader in the waterjet cutting industry. High pressure pumps, cutting heads, abrasive systems, high pressure tubes, original spare parts and a global service network are among the key products and services of the company.