The effects of short pulse laser surface cleaning on porosity formation and reduction in laser welding of aluminium alloy for automotive component manufacture

Shaer, Ahmad Wael Al; Li, L.; Mistry, Anil

doi:10.1016/j.optlastec.2014.05.010

Cited by 126 publications

(45 citation statements)

References 28 publications

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“…Moreover, the presence of lubricants on the surface leads to strong fluctuations of the plasma spectra [14]. The very same conclusion was reached by Alsher et al in their research work, who proposed a preceding cleaning process to laser welding [15]. For this purpose, they suggested to use a nanosecond pulsed fiber laser to remove a 20 microns thickness layer of the substrate surface before welding, comparing the obtained results to those without any cleaning.…”

Section: Introductionsupporting

confidence: 55%

Analysis of the Influence of the Use of Cutting Fluid in Hybrid Processes of Machining and Laser Metal Deposition (LMD)

et al. 2018

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Hybrid manufacturing processes that combine additive and machining operations are gaining relevance in modern industry thanks to the capability of building complex parts with minimal material and, many times, with process time reduction. Besides, as the additive and subtractive operations are carried out in the same machine, without moving the part, dead times are reduced and higher accuracies are achieved. However, it is not clear whether the direct material deposition after the machining operation is possible or intermediate cleaning stages are required because of the possible presence of residual cutting fluids. Therefore, different Laser Metal Deposition (LMD) tests are performed on a part impregnated with cutting fluid, both directly and after the removal of the coolant by techniques such as laser vaporizing and air blasting. The present work studies the influence of the cutting fluid in the LMD process and the quality of the resulting part. Resulting porosity is evaluated and it is concluded that if the part surface is not properly clean after the machining operation, deficient clad quality can be obtained in the subsequent laser additive operation.

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Section: Introductionsupporting

confidence: 55%

Analysis of the Influence of the Use of Cutting Fluid in Hybrid Processes of Machining and Laser Metal Deposition (LMD)

et al. 2018

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“…As a result, the oxides or oils were damaged and extruded out of welding zone, thus, a bond formed between the fresh surfaces under the friction and pressure. Generally speaking, surface characteristics, including surface finish, oxides, coatings, and contaminants on a base metal, are of significant importance to welding or brazing process [20,21]. However, it is not easy to quantitatively study the effects of the surface characteristics during ultrasonic welding.…”

Section: Microstructure Characteristics and Their Effects On The Strementioning

confidence: 99%

Microstructure and Mechanical Properties of Ultrasonic Welded Joint of 1060 Aluminum Alloy and T2 Pure Copper

Liu

Yan-shu

et al. 2017

Metals

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Abstract:The microstructure and mechanical properties of Al/Cu ultrasonic welding joints were investigated. Results show that: (i) the joint strength increased when the welding time increased within a certain range, and a maximal resistant force of 163.04 N was obtained when the welding duration and welding static pressure were 200 ms and 7.2 MPa, respectively; (ii) with a further increase of welding time, the bonding interface was gradually occupied by a thick strip layer of brittle Al 2 Cu (θ 2 ) phase, thus decreasing the strength; (iii) the maximum temperature in the welding region was 360 • C during the welding process, and a recrystallization phenomenon was identified near the welding interface; (iv) the average nanohardness of Cu, the Cu-Al interfacial reaction layer and Al were 1.04 GPa, 1.34 GPa, and 0.53 GPa, respectively, which is consistent with the formation of the intermetallic compound identified by energy-dispersive X-ray spectroscopy (EDS) and XRD analysis.

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“…At the beginning of the simulation, the sample was assumed to be at room temperature. The model was created using a modified SPHysics [55] serial code and was run using an Intel® Core i7 CPU (3. reaching up to 75% [3]. The thermo-physical properties of the base material are listed in Table 1 and are assumed to be temperature-independent during the simulations.…”

Section: Numerical Setupmentioning

confidence: 99%

“…Ejection of the material from the surface is achieved due to the sudden expansion of the surface particles or by evaporation [2,3]. Laser ablation/cleaning was used as one of the successful applications for weld joint surface preparation for Al6014 alloys and Ti6Al4V alloys which have been used for automotive and aero-engine manufacture respectively [3,4].…”

Section: Introductionmentioning

confidence: 99%

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Smoothed Particle Hydrodynamics (SPH) modelling of transient heat transfer in pulsed laser ablation of Al and associated free-surface problems

Alshaer

Rogers

2017

Computational Materials Science

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A smoothed particle hydrodynamics (SPH) numerical model is developed to simulate pulsed-laser ablation processes for micro-machining. Heat diffusion behaviour of a specimen under the action of nanosecond pulsed lasers can be described analytically by using complementary error function solutions of second-order differential equations. However, their application is limited to cases without loss of material at the surface. Compared to conventional mesh-based techniques, as a novel meshless simulation method, SPH is ideally suited to applications with highly nonlinear and explosive behaviour in laser ablation. However, little is known about the suitability of using SPH for the modelling of laser-material interactions with multiple phases at the micro scale. The present work investigates SPH modelling of pulsed-laser ablation of aluminium where the laser is applied directly to the free-surface boundary of the specimen. Having first assessed the performance of standard SPH surface treatments for functions commonly used to describe laser heating, the heat conduction behaviour of a new SPH methodology is then evaluated through a number of test cases for single-and multiple-pulse laser heating of aluminium showing excellent agreement when compared with an analytical solution. Simulation of real ablation processes, however, requires the model to capture the removal of material from the surface and its subsequent effects on the laser heating process. Hence, the SPH model for describing the transient behaviour of nanosecond laser ablation is validated with a number of experimental and reference results reported in the literature. The SPH model successfully predicts the material ablation depth profiles over a wide range of laser fluences 4-23 J/cm 2 and pulse durations 6-10 ns, and also predicts the transient behaviour of the ejected material during the laser ablation process. Unlike conventional mesh-based methods, the SPH model was not only able to provide the thermo-physical properties of the ejected particles, but also the effect of the interaction between them as well as the direction and the pattern of the ejection.2

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The effects of short pulse laser surface cleaning on porosity formation and reduction in laser welding of aluminium alloy for automotive component manufacture

Cited by 126 publications

References 28 publications

Analysis of the Influence of the Use of Cutting Fluid in Hybrid Processes of Machining and Laser Metal Deposition (LMD)

Analysis of the Influence of the Use of Cutting Fluid in Hybrid Processes of Machining and Laser Metal Deposition (LMD)

Microstructure and Mechanical Properties of Ultrasonic Welded Joint of 1060 Aluminum Alloy and T2 Pure Copper

Smoothed Particle Hydrodynamics (SPH) modelling of transient heat transfer in pulsed laser ablation of Al and associated free-surface problems

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