In the metal fabrication industry, the process of cutting steel has undergone tremendous advancements over the years. There are various steel-cutting methods, each with its benefits and drawbacks. However, one of the most popular methods in recent years is waterjet cutting.

In this article, we will explore how waterjet cutting steel works, its applications, advantages, and some essential tips and precautions to consider.

Can A Waterjet Cut Steel?

It’s hard to imagine water cutting through rigid objects, especially something as tough as steel. After all, we typically associate water with softer materials like paper or foam.

But its dynamics change dramatically when water is propelled at high speeds with extreme pressure. In this state, water becomes a powerful force capable of slicing through steel and other hard metals more effectively than mechanical cutting instruments.

You might be surprised at just how well a waterjet machine can cut through steel and the minimal restrictions it has.

How Does Waterjet Cutting Steel Work?

Waterjet technology is a revolutionary method of cutting materials, including steel, by eroding them with supersonic water or water mixed with an abrasive substance. This technique is popular for its cold-cutting process, which means it does not generate heat that can potentially damage the material being cut.

To understand how waterjet cutting steel works, let’s break it down into a few key steps:

1. Pressure Generation

The first step in waterjet cutting steel is generating an intense pressure that will propel the water or water-abrasive mixture towards the material.

An ultrahigh-pressure pump creates a water stream with a maximum pressure of 94,000 pounds per square inch (psi). To put this into perspective, the pressure within a typical fire hose ranges from 390 to 1,200 psi.

2. Pressure to Velocity Conversion

Once the water is pressurized, it must be transformed into a high-velocity stream capable of cutting through the steel. This is achieved through a tiny jewel hole acting as a nozzle. The pressure is converted into velocity as the pressurized water passes through this nozzle.

It creates a stream that is as thin as human hair. This thin, high-velocity stream enables the water jet to cut through even soft materials.

3. Introducing Garnet

While water alone effectively cuts softer materials, it may not be enough to cut through steel. This is where garnet comes into play. Garnet, a natural abrasive material, is introduced into the waterjet stream to boost the cutting power significantly.

Garnet enhances the cutting force by up to 1,000 times when mixed with water. Waterjets can easily slice through steel up to one foot thick with this enhanced cutting power.

4. Escaping the Cutting Head

As the water and garnet mixture cuts through the steel, it escapes the cutting head at an astonishing speed.

In fact, the speed at which the mixture exits the cutting head is almost four times the speed of sound. This rapid speed ensures a clean and precise cut, with minimal heat transfer to the material.

What Types Of Steel Can Be Cut With A Waterjet

Waterjet cutting has proven to be a highly effective and efficient steel-cutting method. Traditional methods rely on heat or mechanical force. But waterjet cutting utilizes a powerful stream of water mixed with abrasive particles to cut through various types of steel.

The following are the types of steel that can be cut with a waterjet:

Tool Steel

Frequently referred to as high-carbon steel, tool steel is specifically crafted to create instruments such as drills, saw blades, and tool bits. With the incorporation of alloys such as tungsten, chromium, and vanadium, its strength, hardness, and resistance to corrosion enhances significantly.

Tool steel achieves remarkable hardness and heat resistance through a tempering process that includes high-temperature exposure, quick cooling, and reheating. Owing to these characteristics and their abrasive nature, tool steels can withstand severe conditions, also suitable for waterjet cutting.

Alloy Steel

Alloy steel is created by the combination of iron with one or more additional elements, each adding distinct properties to the steel. While all steels are alloys, carbon and chromium are notable alloys that contribute to the different types of steel. Alloy steel encompasses a wide range of alloys with varying characteristics.

Elements like tungsten, cobalt, and molybdenum, also found in tool steels, enhance impact resistance and cutting ability. These elements react with iron and carbon to form alloys, making alloy steel well-suited for waterjet cutting.

Stainless Steel

Stainless steel is a very popular material in the production of medical devices and appliances. Yet, its utility extends well beyond kitchen stovetops. The distinctive shine of stainless steel is derived from the chromium alloy. This provides aesthetic charm and bolsters resistance to oxidation, thereby preventing rust and prolonging the metal’s lifespan.

The typical chromium content in stainless steel ranges between 10.5% and 30%. Higher chromium content produces a better sheen when polished and increases corrosion resistance. It’s crucial to differentiate between stainless steel and chrome.

While chrome is an exterior coating applied to carbon steel or other metals, high-chromium stainless steel contains chromium, nickel, and other metals in the alloy. This distinction gives stainless steel its own distinct qualities, making it suitable for waterjet cutting.

Carbon Steel

Carbon steel stands out due to its simplicity, as it primarily consists of carbon without adding other elements. Despite the carbon content being a mere 2% or less by weight, carbon steel is a robust and resilient material suitable for a wide variety of applications.

It’s essential not to confuse carbon steel with cast iron, which possesses a higher carbon content and exhibits greater brittleness.

Carbon steel lacks elements like cobalt, nickel, tungsten, or titanium, common in alloyed metals. While not classified as an alloy, carbon steel is an excellent choice for waterjet cutting due to its strength and versatility.

Applications Of Waterjet Cutting Steel

With its precision cutting capabilities and ability to handle a wide range of materials, waterjet cutting has applications in diverse fields. Here are some of the applications of waterjet cutting steel:

1. High Rise Buildings

High-rise buildings have specific requirements for structural support, especially during natural disasters like earthquakes or hurricanes. Steel is ideal for these buildings as it provides strength and durability.

Waterjet cutting plays a vital role in fabricating steel components for high-rise buildings, including reinforced steel bars, steel plates, beams, pipelines, and steel sections.

The precise cutting provided by waterjet technology ensures that these steel components are accurately shaped and fit perfectly, ensuring the overall structural integrity of the building.

2. Water Pipes

Stainless steel is widely used in underground water pipelines due to its exceptional durability and resistance to corrosion. Whether it’s residential water pipes or drinking water tankers, stainless steel pipes and fittings are the preferred choice for storing and transporting clean water.

Waterjet cutting steel plays a crucial role in shaping and fabricating these pipelines, ensuring a reliable and long-lasting water supply.

3. Agriculture Infrastructure

The agricultural sector has existed for hundreds of years. With the advancement of technology, using materials like steel has greatly benefited the industry. From barns to chicken coops and silos, agricultural structures often rely on steel for their construction.

Waterjet cutting can be used in agricultural steel applications because it allows for the precise cutting of steel components. This ensures that the structures are sturdy and durable.

4. Bridges

Modern bridges are subjected to immense forces from thousands of vehicles crossing them daily. The use of manufactured steel products, combined with secondary processes like galvanization, provides excellent protection against corrosion, ensuring the longevity and reliability of the bridge structures.

Waterjet cutting enables the precise fabrication of various steel components used in bridge structures. Whether it’s steel beams, plates, or sections, waterjet cutting ensures that these components are accurately shaped and free from any defects that could compromise their structural integrity.

5. Warehouses

Steel is a fundamental warehouse component, providing structural integrity and aesthetic appeal. The ease of installation and resistance to corrosion make steel a preferred choice for warehouses.

Waterjet cutting steel allows for the precise fabrication of steel beams, reinforced bars, I-sections, and pipes, forming the primary structural framework of the warehouse.

6. Appliances and Furniture

Steel finds its way into households and businesses through appliances and furniture. The durability and resistance to rust make steel a great choice for long-lasting and reliable household equipment.

Steel furniture, such as chairs, offers longevity and durability, making it a wise investment for offices and homes. Waterjet cutting steel ensures precision and accuracy in shaping steel components for appliances like stoves, refrigerators, washers, and dishwashers.

Advantages Of Waterjet Cutting Steel

Waterjet cutting is an effective and economical solution for cutting steel, from avoiding heat distortion to providing excellent edge quality. Here are the advantages of waterjet cutting steel:

No Heat-Affected Zones

Waterjet cutting utilizes cold cutting methods, unlike other cutting techniques that produce heat. This means that there are no issues like heat distortion or sharpened edges.

This is incredibly helpful for sophisticated metal manufacturing and goods that require additional machining after cutting. Heat-cutting distortion is a major concern for steel fabricators specializing in sophisticated fabrication that demands precise fitting.

Practically Cuts Any Shape or Thickness

Waterjet cutting combines abrasive and high-pressure water to create a cutting stream that is needle-sharp and capable of cutting practically any shape or thickness. This includes bonded laminated products like rubber-lined wear plates and aluminum composite panels.

Waterjet is your best choice if you’re looking for a procedure that can produce superb edges with little to no extra edge treatment and the versatility to cut practically any kind and thickness of materials.

Excellent Edge Quality

Edge quality is one of the most crucial factors in choosing waterjet cutting for designers. Waterjet cutting creates an edge that is uniformly smooth and free of burrs.

The quality of the waterjet edge depends on some factors such as speed, nozzle size, pressure, and abrasive flow rate. By using waterjet cutting, you can often avoid the need for additional finishing, saving you time and enhancing workplace productivity.

Multi-Axis Cutting

Waterjet cutting is not only a multi-axis cutting technology but also provides various cut forms. With a decent waterjet cutter, you can cut in five distinct axes.

This facilitates the creation of complex parts, such as tiny engine parts. The advantages of 5-axis waterjet cutting over traditional 3-axis technologies include increased versatility, cutting speed, and reduced reliance on manual labor.

Environmentally Friendly

Waterjet cutting is an environmentally friendly cutting method. The water used for cutting in a water jet is entirely recycled in a closed-loop system during the cutting process.

The chopped metal is also filtered with water before being sold as scrap. This makes waterjet cutting a highly eco-friendly technique, minimizing waste and reducing its environmental impact.

Tips And Precautions For Waterjet Cutting Steel

Waterjet cutting is a popular method for cutting steel due to its precision and versatility. However, following certain safety tips and precautions is important to ensure a safe working environment. Here are some essential safety equipment and guidelines for waterjet cutting steel:

Safety Equipment

Compared to other industrial operations, waterjet cutting requires specialized safety equipment.

It is crucial to wear hydro jet cutting safety pressure protection gear to protect yourself from the high-pressure water stream. These safety suits can provide a barrier between you and the waterjet, preventing potential injuries.

Glasses

Safety goggles are necessary to avoid eye harm while operating a waterjet cutter. It is important to check whether your safety glasses have ISO approval, ensuring their effectiveness in protecting your eyes from flying debris or water droplets.

Ear Protection

The noise generated by a waterjet cutter can be extremely loud and may cause damage to your ears. Therefore, it is essential to wear the proper ear protection, such as earplugs or earmuffs, to prevent hearing loss or discomfort.

Safety Gloves

There are several varieties of safety gloves available for waterjet cutting. It is advisable to wear Kevlar-reinforced cut-resistant safety gloves, as they provide the necessary protection from sharp edges and potential cuts.

These gloves are specifically designed for waterjet cutting and can ensure your safety while operating the machine.

Extra Security

In addition to the basic safety equipment, you should take extra security measures to protect yourself further. This includes wearing helmets, knee and shin guards, and knee pads to prevent any potential injuries in case of accidents.

However, it is important to note that the waterjet stream should never be approached, even with extra safety measures.

Sufficient Equipment

When using a waterjet cutter, it is essential to have high-quality equipment. Even when you take every safety measure, using a low-quality machine might result in accidents.

Investing in high-quality equipment can ensure a safer working environment and save you money in the long run.

Instruction Manual

Each waterjet cutter is unique and has its own set of safety measures. Therefore, it is important to thoroughly read the user handbook before using the waterjet cutter for the first time. 

Familiarize yourself with your machine’s specific safety PPE equipment and operating procedures to avoid any potential hazards.

Drunken State

Under no circumstances should you operate a waterjet cutter or any other piece of heavy industrial machinery while intoxicated or under the influence of any narcotics, including sedatives. This can impair your judgment and reaction time, increasing the risk of accidents and injuries.

Company Policies

Before using equipment or joining the workforce, it is important to check whether your business has an appropriate safety policy in place.

Ensure that the workplace follows the Work Health and Safety (WHS) rules and regulations to provide a safe working environment for everyone.

Learn How To Use The Motion Controls

Waterjet machines can move at a maximum speed of 100 inches of material per minute. This rapid movement makes playing tag with a cheetah impossible, emphasizing the importance of keeping your hands far from the machine while it is in operation.

It is always better to pause and recheck everything if something isn’t cutting as expected. It is preferable to perform a task a little more slowly than to risk injury and fail to complete it at all.

Conclusion

Waterjet cutting steel has revolutionized the metal fabrication industry with its precision, and efficiency. Its ability to cut through various steel materials without generating heat-affected zones makes it an ideal choice for a wide range of applications.

By following the tips and precautions mentioned above, professionals can harness the full potential of waterjet cutting steel. They can unlock endless possibilities for precise and efficient steel cutting. If you are looking for an exceptional waterjet cutter that will meet your steel cutting needs, don’t hesitate to look through our collection today.

FAQ for Waterjet Cutting Steel

How fast can a water jet cut steel?

A waterjet cutter can cut through a 6mm thick piece of stainless steel at a speed of 6 inches per minute. For a 20mm thick stainless steel sheet, the cutter can achieve a cutting speed of approximately 2 inches per second using the same cutter and orifice diameter.

What is the maximum thickness that a water jet can cut?

In general, abrasive waterjets can effectively cut through materials up to 12 inches thick. Some claim to be able to cut even thicker materials.

Can a water jet cut bone?

Yes, water jet technology can cut bone and bone cement. Using abrasive waterjets, especially when combined with an abrasive material, can result in higher-quality cuts for biomaterials like bone and bone cement.