Can you laser mark aluminum?

Aluminum is widely used in 3C electronics, automobiles, aerospace and other fields due to its lightweight, corrosion resistance and excellent conductivity. However, aluminum’s high reflectivity, high thermal conductivity and surface oxide layer make its laser marking a technical challenge. This article will start from the physical properties of aluminum, explore the feasibility, technical difficulties and solutions of laser marking aluminum, and analyze the application prospects based on actual cases.

Why Can’t Diode Lasers Directly Mark Bare Aluminum?

There are three main reasons why diode lasers (usually 450nm wavelength blue light) are difficult to directly mark bare aluminum:

• Extremely low absorption rate: bare aluminum absorbs less than 5% of 450nm wavelength lasers, while 1064nm fiber lasers absorb 18-23%, and ultraviolet lasers (355nm) absorb 30-40%
• Heat conduction loss: The thermal conductivity of aluminum is as high as 237W/m·K, and the continuous power of diode lasers (usually <10W) is difficult to form effective heat accumulation on the surface
• Oxide layer barrier: The natural aluminum oxide (Al₂O₃) layer is highly reflective to visible light lasers and requires at least 50W peak power to penetrate

Solution:

• Use MOPA fiber laser (1064nm, 50-100W) or UV laser (355nm, 3-10W)
• Surface pretreatment: Sandblasting (roughness Ra>1.2μm) or anodizing can increase the absorption rate to 60%+
• Use laser activator (such as CerMark spray) to form an absorption layer

 Why Does Xtool F1 Require CerMark Spray?

Xtool F1 is a cost-effective diode laser engraving machine. When marking metal, the direct processing effect is poor, but it can be significantly improved with CerMark spray. The following is an analysis of the technical principles, operation methods and solutions. ​

Limitations of bare metal laser marking​

1. Low absorption rate of semiconductor laser on metal surface​:The absorption rate of 450nm blue semiconductor laser of Xtool F1 on the surface of stainless steel and aluminum alloy is less than 10%, resulting in whitish and blurred marking, poor wear resistance and contrast. ​
2. Risk of material damage due to heat accumulation​:Increasing power (>50W) or reducing speed (<200mm/s) can easily cause metal carbonization and scorch cracks, and thin-walled parts may also deform.

The principle of “chemically enhanced marking” achieved by CerMark spraying

• Chemical reaction mechanism of silicate coating:CerMark LMM-6000 contains silicate formula. After laser irradiation, SiO₂ reacts with the metal matrix to form a metal silicate composite layer. The marking depth is 5-20μm and the hardness is ≥6H, which is far superior to traditional processes.
• Military-grade durability verification:Passed the 1000-hour salt spray test of ASTM B117 standard, with strong corrosion resistance, no peeling and fading, and the cost per square meter is US$0.45, which is only 1/3 of electrolytic engraving.

Standardized operating procedures (ISO 8501-1 certified)

Comparison of alternatives: Why must you choose CerMark?

CerMark achieves 80% of the performance of electrolytic engraving at 1/3 of the cost, which is the optimal solution to balance quality and budget. Through chemical reaction, Xtool F1 with CerMark spray breaks through the limitations of metal marking, suitable for high-end scenes, and professional results can be obtained by standard operation.

 How to Prevent Nano-Aluminum Dust Hazards?

Nano aluminum dust (particle size <100nm) is not only a core material for industrial production, but also a dual source of explosion risk and health hazards due to its high reactivity and suspension characteristics. According to statistics, the probability of explosion in an uncontrolled nano aluminum dust environment increases by 300%, and long-term exposure can lead to pulmonary fibrosis. Based on the joint standards of OSHA and NFPA, LS explains the full-process prevention and control technology of nano aluminum dust in detail, covering three dimensions: dust collection, environmental monitoring and personnel protection.

Fatal risks of nano aluminum dust

1. Explosive hazards

• Minimum explosive concentration (MEC): Nano aluminum dust only needs 30g/m³ to cause deflagration (ordinary aluminum powder needs 500g/m³).
• Extremely low ignition energy: 0.1mJ static spark is enough to trigger an explosion (human walking can generate 10mJ static electricity).

2. Health damage mechanism

• Alveolar penetration: Particles with a particle size of less than 0.1μm can directly reach the alveoli and trigger oxidative stress.
• Neurotoxicity: The blood-brain barrier penetration rate is as high as 15%, which is positively correlated with the risk of Alzheimer’s disease.

Three-level prevention and control system: closed-loop protection from source to terminal

1. Dust collection and filtration system

▍HEPA-ULPA three-level filtration architecture

• First level (pre-filtration): metal mesh primary filter, intercepting >5μm particles, with an efficiency of 90%.
• Second level (HEPA): H14 filter element, capturing 99.995% of 0.3μm particles.
• Third level (ULPA): U17 filter element, with a filtration efficiency of 99.999% for 0.12μm particles.

▍Key parameters for system operation

• Air volume matching: ventilation rate ≥12 times/hour (calculated based on workshop volume).
• Pressure difference monitoring: automatic alarm and backwash cleaning when filter element resistance >500Pa.
• Maintenance cycle: ULPA filter element is forced to be replaced every 6 months (even if the pressure difference limit is not reached).

2. Real-time environmental monitoring and linkage control

▍Explosion-proof and health dual-indicator monitoring

• Monitoring items Safety threshold Exceeding response measures
• Oxygen content >18% (NFPA 70E) Inject nitrogen to dilute to 19.5%-23.5%
• Ozone concentration ≤0.08ppm Start activated carbon adsorption + fresh air system
• Dust concentration <20% MEC Shutdown and trigger dry powder explosion suppression device

▍Core sensor technology

• Laser scattering particle counter: Real-time detection of 0.1-10μm particle concentration, accuracy ±5%.
• Electrochemical oxygen sensor: response time <3 seconds, life 2 years (needs annual calibration).
• PID ozone detector: range 0-1ppm, resolution 0.01ppm.

3. Personnel protective equipment (PPE) upgrade

• Respiratory protection: powered air-supply respirator (APF=1000) with ULPA filter.
• Full body protection: anti-static coverall (surface resistance <1×10⁹Ω), double-layer seal at seams.
• Emergency measures: eyewash + chemical shower equipment within 10 meters of the work area.

Safety transformation case of nano aluminum dust workshop

Case 1: Aluminum alloy 3D printing workshop

Risk point: Nano aluminum powder particle size 50-80nm, strong diffusion.

Transformation plan:

Install a side suction HEPA-ULPA filtration system (air volume 5000m³/h).

Deploy 16 ozone/oxygen content monitoring points, and connect the data to the central PLC.

All employees are equipped with Tyvek® 600 protective clothing + 3M Versaflo TR-300 respirator.

Effect: Dust concentration dropped from 35g/m³ to 0.8g/m³, and there were no explosion accidents throughout the year.

Case 2: Lithium battery negative electrode material production line

Challenge: Graphite/nano aluminum composite dust easy adsorption equipment.

Solution:

Adopt wet dust removal (water mist particle size <10μm) + ULPA dry filtration composite system.

Install infrared spark detection + CO₂ rapid fire extinguishing device at the outlet of the crusher.

Results: The dust explosion risk level was reduced from Class II to Class I, and insurance costs were reduced by 40%.

Through the three-in-one strategy of engineering control, monitoring and early warning, and personal protection, the hazards of nano-aluminum dust can be effectively controlled to an acceptable risk level (ALARP principle) to ensure personnel health and production safety.

Why Do EV Batteries Require UV Laser Marking?

With the rapid development of the global electric vehicle industry, the annual output is expected to exceed 30 million vehicles in 2025. The safety and reliability of power batteries have become the top priority of the industry. Traditional inkjet coding has the problem of easy falling off, and fiber lasers have a large thermal impact. In contrast, UV laser marking has become an ideal choice to meet strict standards such as IEC 62133-2 and UN38.3 due to its unique “cold processing” characteristics. The following will analyze in detail why UV laser marking has become the “golden process” for power battery marking. ​

1. Thermal sensitivity control: the key to ensuring battery safety​

(1) Lithium ion migration risk

Power battery cathode materials, such as NCM811, are extremely sensitive to temperature. When the temperature exceeds 50°C, irregular lithium ion migration will occur, which will in turn cause local lithium precipitation and lead to lithium dendrite growth. This will not only affect battery performance, but also increase the risk of internal short circuits in the battery by 300% (data from CATL laboratory research), seriously threatening the safety of battery use. ​

(2) UV laser cold processing principle

The energy of a single photon of 355nm UV laser is as high as 3.5eV. It can directly destroy the chemical bonds on the surface of the material without relying on thermal energy, achieving “cold processing” with a heat-affected zone of less than 5μm. Comparative experimental data show that when UV laser marking is used, the temperature of the battery shell only rises by 2.8℃; while the fiber laser causes the shell temperature to rise by 42℃, which shows the significant advantages of UV laser in thermal control.

(3) Compliance with IEC 62133-2 mandatory requirements

The IEC 62133-2 standard clearly stipulates that the heat input during the battery marking process must be strictly controlled to ensure that the battery shell temperature does not exceed 40℃. Among the existing technologies, UV laser marking is the only solution that can fully meet this requirement, providing reliable protection for battery safety.

2. Electrolyte corrosion resistance: coping with harsh use environments​

(1) Electrolyte corrosion scenarios​

The main component of the electrolyte inside the power battery is LiPF₆ (lithium hexafluorophosphate), which will decompose into HF (hydrofluoric acid) when it comes into contact with water, forming a PH3 acidic environment. According to the UN38.3 test protocol, the battery label must be able to withstand continuous immersion for 240 hours in such harsh environments without corrosion. ​

(2) Characteristics of UV laser marking

UV laser marking can form a honeycomb microporous structure with a depth of 0.02-0.05mm and a pore size of less than 3μm on the surface of the aluminum shell, effectively preventing the penetration of electrolyte, and the permeability is reduced by 92% compared with other methods. At the same time, the laser action can also induce the formation of a 10nm thick Al₂O₃ passivation layer to enhance the surface corrosion resistance. After 240 hours of immersion, its surface roughness only increased by 0.12μm; while the shedding rate of traditional inkjet coding in this environment is as high as 100%.

(3)Comparison of measured data

 Six core advantages

1. Permanent traceability: After – 40℃~150℃ cycle and vibration test, the QR code can be scanned within the 10-year life cycle
2. Nano precision: supports 0.1mm micro QR code, 3000 characters/cm² high-density information
3. Environmental certification: no ink pollution, passed REACH regulation certification
4. High-speed production: 5m/s galvanometer speed, single battery marking < 0.8 seconds, suitable for 100PPM production line
5. Multi-material application: compatible with aluminum shell, copper pole ear, PP insulation film and other materials
6. Intelligent interconnection: joint control with MES system, “one code one core” binding, recall efficiency increased by 90%

In summary, UV laser marking has significant advantages in temperature control, corrosion resistance, precision and production efficiency, and is a key technology for power battery marking.

4. Industry application cases

(1)Tesla 4680 battery

Using TRUMPF TruMark 6230 UV laser, 0.03mm deep DMC code is engraved on the steel shell surface, and the 160℃ thermal runaway test is passed without blur.

(2)CATL Kirin Battery

HGU UV laser equipment marks on 1.5mm thick aluminum alloy shell, HAZ width is 4.7μm, and the production line yield reaches 99.98%.

(3)BYD Blade Battery

The Han’s UV laser system achieves dynamic coding of 120 cells per minute, and the QR code misreading rate is less than 0.001%.

UV laser marking technology breaks through the two major technical bottlenecks of heat sensitivity and corrosion resistance with its “cold processing” characteristics, becoming the only compliant choice for power battery marking. As the penetration rate of new energy vehicles continues to rise, this technology will accelerate the replacement of traditional processes and provide underlying guarantees for the global electrification process.

 How to Calculate ROI for Industrial Marking Systems?

Industrial laser marking systems can easily cost tens of thousands of dollars, which often makes corporate decision makers hesitate. But real data shows that a 20W fiber laser system can pay back within 14 months, with an annual comprehensive income of more than $100,000. This section will take you step by step to dismantle the investment return model of the laser marking system through reusable calculation formulas, comparative measured data and automotive parts industry cases.

1. Core calculation formula for ROI of laser marking system

(1)Basic formula

Investment payback period (month) = total initial investment / monthly net income
Annualized ROI = (annual net income – annual operating cost) / total initial investment × 100%

(2) Decomposition of cost-benefit factors

2.Industry comparison data

3. Quickly estimate your ROI in three steps

Calculate current annual expenditure
(labor + consumables + waste + maintenance)
Estimated laser system benefits
Labor savings = original labor cost × 70%
Waste reduction = annual output × (original defect rate – 0.5%) × unit cost
Productivity benefits = (laser speed – original speed) × annual working hours × unit profit
Online tool verification
Use the TRUMPF/Han’s Laser official website ROI calculator (input parameters to automatically generate reports)