Improving surface striation and kerf taper of hybrid Al/CFRP stacks using dual-pass abrasive waterjet slotting strategy

The stacked carbon fiber reinforced plastic (CFRP) laminate and metallic plate are widely used in the aerospace industry to improve structural performance and reliability. Abrasive waterjet (AWJ) machining is a promising technique for cutting hybrid metallic/CFRP stacks with high efficiency and versatility, while the machining defects including kerf taper, striation, and craters are prevalent when using the single-pass AWJ cutting method. This study aims to develop a dual-pass AWJ cutting strategy to improve surface quality and reduce machining-induced damage of Al/CFRP stacks without compromising machining efficiency. The kerf taper was respectively reduced by up to ~ 63% and ~ 37% for aluminum plate and CFRP laminate using the proposed dual-pass abrasive waterjet slotting strategy. Striations were effectively reduced, resulting in improved kerf surface quality and significantly lower maximum peak-to-valley height. Straight/smooth kerf profiles were obtained by employing the dual-pass strategy with relatively low hydraulic pressure levels.