Effect of Laser Welding on Intermetallic Phase Formation between Aluminium Alloys Foam and Steel Bulk Skin

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Abstract

Metal foams are conquering an increasing interest in the industrial stage. Aluminium foams have ahigh potential for use in weight-sensitive construction parts. The stiffness to weight ratio is themain criteria for material selection in light-weight design. Many processes are available tomanufacture metal foams classified according to the state in which the metal is processed (liquid,solid, vapour or a solution of metal ions) and similarly different techniques can be applied to jointhe foam to bulk elements. In this context, the aim of this work is to perform an experimentalstudy of laser welding for realising parts with an aluminium foam core (AlSi10 and AlSi0.6Mg1) anda steel external skin. The goal of the paper is to point out the feasibility of the process with theformation of an intermetallic phase between steel and aluminium and then the influence of themain process parameters. The experimentation was carried out in two steps: a preliminary studyabout an overlapped joint between steel and foam sheets and then the joining of steel hollowprofile and aluminium foam obtained by a precursor material foamed directly inside the profile. A fullfactorial plan was designed by varying different process parameters referred to the laser (power ofthe laser source, execution speed, heat input and focal distance of the laser beam) while, exceptthe precursor material, all the factors relative to the foam were kept constant. As results anintermetallic phase formation between aluminium foams and a stainless steel sheets and mouldshave been obtained observed by micrograph examination.

Autore Pugliese

Tutti gli autori

  • R. Surace; G. Marinzuli; L.A.C. De Filippis; A.D. Ludovico

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Anno di pubblicazione

2014

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