Laser cutting produces a heat-affected zone, but it is localized near the cutting zone.

Other factors

Laser processing is more sensitive to material quality than abrasive waterjet cutting. For example: Hot-rolled steel presents serious quality problems in laser cutting because of the surface scale that tends to melt into the metal to create an undesirable surface finish. Laser cutters typically require a smooth surface texture, or their assist gas and focus can be altered. That will affect the quality of the cut. Abrasive waterjet is oblivious to that problem.

Laser cutting also can create more stresses in material than abrasive waterjet cutting. Titanium, for example, can be combustible so the heat from a laser could destroy the part if cut with oxygen.

“Waterjet is displacing laser in titanium and Inconel applications in which there is concern about temperature on the edge and a recast layer,” Sterner said.

Also, in applications in which a re-cast layer is undesirable, waterjet cutting can be used to make a cleaner cut.

Lastly, both plasma and laser cutting create an oxide layer that requires removal prior to welding. Abrasive waterjet technology does not create such a layer, and edges cut with that technology typically are clean and ready for welding, Sterner said.

LAI uses abrasive waterjet for many hole drilling applications that have tight tolerances.

Some components LAI manufactures can have as many as 150,000 holes with demanding tolerances.

“When it comes to drilling holes with waterjet, we're very good at it,” Sterner said.

He said his company uses abrasive waterjet to achieve tolerances of +/- 0.003 in. and lasers to drill holes with tolerances of +/- 0.001 in. All five of LAI's fabrication facilities are ISO 9001:2000 and AS9100 certified. The company also offers NADCAP certified non-conventional machining and welding processes.

MC Machinery Systems' Giannotte said abrasive waterjet cutting is a growing technology. Waterjet cutting is a good business even for small companies that are seeing increased demand for this technology.

“A lot of job shops are upgrading to these newer technologies because they are an ideal way to cut, particularly in parts where the heat affected zone is critical,” Giannotte said.

While not every machine shop invests in waterjet technology, some companies offer this service.

Southwest Waterjet Corp. (www.southwestwaterjet.com) offers precision waterjet cutting for a variety of applications, including sign companies, machine shops and other companies that require the precision of the technology, but don't have the equipment.

Mike Guden Sr., owner of Southwest Waterjet, said his company can cut large steel plate or thin aluminum sheets to produce smaller, more manageable pieces to work with.

“(Our customers) have us do the waterjet cutting because it saves them on their coolant and cutting tools. It's cheaper for them to have us use our waterjet technology,” Guden said.

Southwest Waterjet has one Omni cutting machine, and Guden is planning to purchase a second machine this year.

Guden said waterjet cutting is cheaper than other types of cutting, including laser cutting, and it can make cleaner cuts. In the hot Arizona climate, Guden said he needs a chiller to cool the water for his machines because hot water wears out the machine components faster.

“Margins drive profits and waterjet is the most profitable manufacturing technology today. Waterjet cutting plays an important role in today's manufacturing environment. Some use waterjet to rough a piece and EDM to finish it,” Guden said.

LAI knows the importance of abrasive waterjet's versatility for cutting various materials.

With revenues expected to reach $58 million in 2008, that company continues to expand by taking on more of its customers' supply chains.