Method for Quantifying the Criticality of Laser Cutting Defects: Influence of Morphologies on Design Parameters

Laser cutting is an established, multi-physical process widely adopted by the metallurgical industry. However, this fast industrialisation has had a significant impact on quality control. Reviews from 2008 to 2022 primarily focus on single-criterion quality approaches, targeting defects like the Heat-Affected Zone, surface roughness, or kerf geometry, rather than adopting comprehensive methods. In addition, these studies show that cutting quality can be improved by selecting laser manufacturing parameters and part parameters such as thickness or material. However, the influence of part morphology remains underexplored. Following this observation, this study proposes a generic and complete method adapted from the Failure Modes, Effects and Criticality Analysis, allowing the evaluation of the criticality of all cutting defects in a part. It focuses on six laser cutting defects defined in an international standard and three types of morphology: arcs, angles and segments. The aim is to establish a holistic approach linking morphologies to all defect types. Industrial application reveals that thermal defects are highly influenced by morphology. Burrs and adherent slag are particularly critical in arcs and angles, while segments are less sensitive. This analysis establishes design limits and offers practical tools to improve industrial laser cutting through detailed quality assessments.