Interaction mechanisms and damage formation in laser cutting of CFRP laminates obtained by recycled carbon fibre

Abstract The increase in the use of composite materials poses the problem of their disposal/recycling after the End of Life (EOL). Different strategies were developed to recycle composite material, resulting in the availability of new raw materials, characterised by overall good mechanical properties and significantly low cost. However, the applicability of these materials to industrial production also depends on the possibility of producing and processing them with likewise available technologies. Among the production and processing technologies that can be adopted for recycled composite materials, resin infusion under flexible tooling (RIFT) and laser machining, respectively, stand out above all due to the high production/machining speed compared to the cost. This paper investigates the possibility to apply both these technologies to carbon fibre–reinforced polymer laminates obtained by adopting recycled carbon fibres. Recycled CFRP plates of about 2.7 mm in thickness were produced by RIFT and characterised in tensile and flexural tests. After mechanical characterisation, cutting tests were performed by using a 450 W QCW fibre laser, varying the pulse power, the pulse length, and the pulse overlap. The kerf geometries and the HAZ extension were measured at the upper and bottom parts as well as in the section. Analysis of variance was adopted to define which and how the process parameters affect the kerf dimension and HAZ extension. Results showed that it is possible to cut the composite at a cutting speed up to 2000 mm/s, obtaining, in the best conditions, narrow kerf, limited HAZ, and taper angle of about 0°. Graphical abstract