Yes, you can cut aluminium with a waterjet cutting machine, and it’s one of the best ways to do so. Waterjet cutting is widely used across industries because of its precision, efficiency, and ability to cut without heat distortion.

Whether you’re working on intricate designs or heavy-duty industrial applications, waterjet cutting delivers clean and accurate results.

In this blog, we will explore everything you need to know about cutting aluminium with a water jet, including key factors to consider, benefits, tips for achieving the best quality results, limitations, pressure requirements, and how to choose the best service provider.

What Key Factors Should You Consider When Waterjet Cutting for Aluminum?

When using a waterjet cutting machine for aluminium, several factors play a crucial role in ensuring high-quality and efficient cutting.

Here are 10 key considerations:

Thickness of the Aluminum

Waterjet cutting can handle a wide range of aluminium thicknesses, from thin sheets to thick blocks. However, the cutting speed and water pressure need adjustments based on thickness. Thicker aluminium requires a slower cutting speed and higher pressure to maintain precision and avoid uneven edges.

Type of Aluminum Alloy

Aluminium comes in various alloys, each with different properties. Softer alloys, like 1100 aluminium, cut faster, while harder alloys, such as 7075 aluminium, may require higher pressure and an abrasive water jet to ensure a clean cut.

Abrasive or Pure Waterjet?

For thin aluminium sheets, a pure water jet may be sufficient. However, for thicker or harder aluminium, adding an abrasive (like garnet) enhances efficiency, reduces cutting time, and results in better edge quality.

Water Pressure Settings

Water pressure settings are crucial for achieving precise cuts. Typically, pressures between 50,000 and 90,000 PSI are used for aluminium. Lower pressure can result in incomplete cuts, while excessive pressure can cause unnecessary material wear.

Edge Quality Requirements

If a smooth, burr-free edge is required, cutting speed and abrasive concentration must be adjusted. Slowing down the cutting process improves edge quality and minimizes the need for secondary finishing processes.

Part Geometry and Complexity

Waterjet cutting is excellent for intricate and complex shapes. However, if the design includes sharp corners or small details, adjusting the feed rate and pressure can prevent material warping and unwanted deviations.

Kerf Width Considerations

The kerf, or cut width, depends on the nozzle size and water pressure. Understanding kerf width helps in designing parts accurately to achieve the desired dimensions.

Cutting Speed Optimization

Faster cutting speeds may lead to rough edges, while slower speeds ensure a smoother finish. Optimizing cutting speed based on material thickness and design complexity improves overall efficiency.

Workpiece Support and Fixturing

Properly securing the aluminium sheet or block prevents movement during cutting, reducing errors and ensuring a precise cut.

Cost Considerations

While waterjet cutting is cost-effective, factors like material thickness, cutting time, and abrasive consumption impact overall costs. Choosing the right settings helps balance cost and efficiency.

Important Tips To Get the Best Quality Results When Waterjet Cutting Aluminum

Achieving the best quality results when waterjet cutting aluminium requires careful planning and precise execution. Here are 10 essential tips to ensure optimal cutting quality:

Use the Right Nozzle Size

Choosing the correct nozzle size determines the precision of the cut. An appropriately sized nozzle ensures the right balance of water flow and pressure, reducing the risk of jagged edges or uneven cuts.

Adjust Cutting Speed According to Thickness

Cutting speed must be carefully adjusted based on the thickness of the aluminium. Thicker aluminium requires a slower cutting speed to maintain precision, whereas thinner sheets can be cut at higher speeds.

Optimize Water Pressure

Water pressure plays a crucial role in achieving clean cuts. Most aluminium cutting applications require pressures between 50,000 and 90,000 PSI. Too low a pressure may result in incomplete cuts, while excessive pressure may cause excessive material wear.

Use High-Quality Abrasives

When cutting thicker or harder aluminium, using premium-grade garnet abrasives helps achieve smoother, cleaner cuts with minimal material waste.

Prevent Material Warping

Properly securing the aluminium sheet or block prevents shifting during the cutting process, which can result in inaccuracies. Additionally, adjusting waterjet parameters prevents warping and distortion of the material.

Regularly Maintain the Waterjet Machine

Routine maintenance, including cleaning and checking nozzles, ensures the machine operates at peak efficiency and extends its lifespan.

Consider Taper Compensation

Adjusting for taper in the cut path can help achieve more precise dimensions, particularly for intricate or high-tolerance components.

Use CAD Software for Precision Design

Optimizing the cut path through CAD software minimizes material waste, enhances accuracy, and improves overall cutting efficiency.

Minimize Piercing Time

Reducing the piercing time ensures less stress on the aluminium, which contributes to a smoother cut with fewer imperfections.

Test on Scrap Material First

Before beginning a production run, testing on scrap aluminium allows you to fine-tune settings and verify the quality of the cut, avoiding costly mistakes.

How Much Pressure to Cut Metal?

The amount of pressure required for waterjet cutting depends on the type and thickness of the metal. Here’s a breakdown of recommended pressures for common metals:

Waterjet Cutting Pressure Requirements:

• Aluminium: 50,000-90,000 PSI (thinner sheets require lower PSI, thicker aluminium needs higher pressure)
• Stainless Steel: 60,000-90,000 PSI
• Titanium: 60,000-87,000 PSI
• Mild Steel: 55,000-85,000 PSI
• Copper and Brass: 50,000-80,000 PSI

Factors Affecting Waterjet Cutting Pressure:

1. Material Hardness: Harder metals require higher pressure to cut effectively.
2. Thickness: Thicker materials require more pressure and an abrasive water jet to maintain precision.
3. Nozzle Type and Diameter: A larger nozzle may require higher pressure to maintain the same cutting accuracy.
4. Cutting Speed: Higher pressures allow for faster cutting speeds without compromising precision.

How to Choose the Best Waterjet Cutting Service for Aluminum?

Selecting the exemplary waterjet cutting service is crucial to ensuring high-quality results for your aluminium projects.

Here are key factors to consider when choosing a waterjet cutting provider:

Experience and Expertise

Look for a service provider with years of experience in waterjet cutting, particularly in aluminium processing.

Advanced Waterjet Technology

Ensure the provider uses high-precision waterjet cutting machines with advanced features such as dynamic waterjet technology and automated cutting systems.

Material Compatibility

Confirm that the service provider specializes in cutting aluminium and other materials relevant to your project.

Tolerance and Precision Standards

Choose a company that can achieve tight tolerances (±0.003 inches) for intricate or high-precision aluminium parts.

Cutting Speed and Turnaround Time

Fast turnaround times are crucial for meeting project deadlines. Ask about estimated delivery times before placing an order.

Cost-Effectiveness

Compare pricing structures and ensure there are no hidden costs. A reputable service should offer competitive pricing without compromising quality.

Customer Reviews and Testimonials

Check online reviews and testimonials to gauge customer satisfaction with their waterjet cutting services.

Customization Options

Ensure the provider can handle custom and complex designs for specific project requirements.

Quality Control Measures

A reliable service provider should have stringent quality control measures in place to guarantee accuracy and consistency in their cuts.

Choose SS Engineering Works for Waterjet Cutting

At SS Engineering Works, we provide state-of-the-art waterjet cutting services with expert craftsmanship, competitive pricing, and a commitment to delivering precision-cut aluminium components.

Conclusion

Waterjet cutting is the best method for cutting aluminium due to its precision, versatility, and ability to maintain the material’s integrity. Unlike traditional cutting methods, waterjet cutting eliminates the risk of heat distortion while delivering clean, accurate, and smooth edges.

By following best practices—such as optimizing water pressure, choosing the proper nozzle, and using high-quality abrasives—you can ensure the best quality results. Selecting a trusted waterjet cutting provider like SS Engineering Works further guarantees precision, cost-effectiveness, and efficient project execution. 

Whether you’re in aerospace, automotive, or manufacturing, waterjet cutting is a reliable solution for achieving high-quality aluminium components.