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During this research, experimental rolled homogeneous armour steel was cast, annealed and laser cut to form an appliqué plate. This Martensitic–Bainitic microstructure steel grade was used to test a novel means of engineering lightweight armour. It was determined that a laser cutting speed of 1200 mm/min produced optimum hole formations with limited distortion. The array of holes acts as a double-edged solution, in that they provide weight saving of 45%, providing a protective advantage and increasing the surface area. Data collected were used to generate laser cut-edge hole projections in order to identify the optimum cutting speed, edge condition, cost and deformation performance. These parameters resulted in the generation of a surface, with less stress raising features. This can result in a distribution of stress across the wider surface. Provided that appropriate process parameters are used to generate laser cut edges, then the hardness properties of the surface can be controlled. This is due to compressive residual stresses produced in the near edge region as a result of metallurgical transformations. This way the traverse cutting speed parameter can be adjusted to alter critical surface characteristics and microstructural properties in close proximity to the cut-edge. A relationship was identified between the width of the laser HAZ and the hardness of the cut edge. It is the thickness of the HAZ that is affected by the laser process parameters which can be manipulated with adjusting the traverse cutting speed.
During this research, an experimental method for testing a material used in testing a non-ferrous metals was cast, annealed and laser cut to form an appliqué plate. It was determined that a laser cutting speed of 1200 mm / min produced optimum hole formations with limited distortion. The array of holes acts as a double-edged solution, in that they provide weight saving of 45%, providing a protective advantage and increasing the surface area. These parameters resulted in the generation of a surface, with less stress raising features. This can result in a distribution of stress across features Provided that appropriate process parameters are used to generate laser cut edges, then the hardness properties of the surface can be controll ed. This is due to compressive residual stresses produced in the near edge region as a result of metallurgical transformations. A it was the thickness of the HAZ that is affected by the laser process parameters which can be manipulated with adjusting the traverse cutting speed.