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<p>This study evaluates the efficacy and impact of fiber-laser cleaning as a more sustainable, non-chemical alternative to traditional chemical stripping for removing polyurethane paint and epoxy primer from Al2024-T3 Alclad aluminum sheets widely used in the aeronautic sector. Current chemical methods pose significant risks due to volatile organic compounds and hazardous waste, motivating the search for safer, automated, and environmentally friendly processes. The investigation compared the effect of the chemical stripping and optimized laser parameters on the Al2024-T3 alclad alloy through a comprehensive analysis. A full Design of Experiment (DoE) was used to vary laser cleaning parameters, followed by evaluation of surface morphology (optical, SEM, 3D profilometry), and mechanical properties (hardness, yield strength). The main findings indicate that within a qualified process window (Pa 100%, Ssp 25–50&#xa0;µm, Rep 2–3), fiber-laser cleaning achieves complete paint removal with a resulting surface finish and mechanical response comparable to the chemical stripped benchmark. The laser treatment caused no measurable loss of cladding material and no degradation of the core’s yield strength, suggesting the thermal impact is negligible. Optimized parameters were identified in treatment 1 (Pa 100%, Ssp 25&#xa0;µm, Rep 2) for obtaining the highest surface quality, while treatment 23 (Pa 100%, Ssp 50&#xa0;µm, Rep 3) provided the best balance between quality and productivity. These results validate fiber-laser cleaning as a viable, high-performance, and more sustainable replacement for chemical stripping of the polyurethane paint and epoxy primer in aircraft operations.</p>

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Optimisation of fibre laser cleaning for paint and primer removal on Al2024-T3 Alclad sheets for the aeronautic sector

  • 期刊论文

  • 发表日期：

    2026年5月2日

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  • Emanuele Mingione,
  • Gianluca Rubino

摘要

This study evaluates the efficacy and impact of fiber-laser cleaning as a more sustainable, non-chemical alternative to traditional chemical stripping for removing polyurethane paint and epoxy primer from Al2024-T3 Alclad aluminum sheets widely used in the aeronautic sector. Current chemical methods pose significant risks due to volatile organic compounds and hazardous waste, motivating the search for safer, automated, and environmentally friendly processes. The investigation compared the effect of the chemical stripping and optimized laser parameters on the Al2024-T3 alclad alloy through a comprehensive analysis. A full Design of Experiment (DoE) was used to vary laser cleaning parameters, followed by evaluation of surface morphology (optical, SEM, 3D profilometry), and mechanical properties (hardness, yield strength). The main findings indicate that within a qualified process window (Pa 100%, Ssp 25–50 µm, Rep 2–3), fiber-laser cleaning achieves complete paint removal with a resulting surface finish and mechanical response comparable to the chemical stripped benchmark. The laser treatment caused no measurable loss of cladding material and no degradation of the core’s yield strength, suggesting the thermal impact is negligible. Optimized parameters were identified in treatment 1 (Pa 100%, Ssp 25 µm, Rep 2) for obtaining the highest surface quality, while treatment 23 (Pa 100%, Ssp 50 µm, Rep 3) provided the best balance between quality and productivity. These results validate fiber-laser cleaning as a viable, high-performance, and more sustainable replacement for chemical stripping of the polyurethane paint and epoxy primer in aircraft operations.