Process Monitoring and Numerical Analysis of Mechanism of Laser Forming in Open-Cell Aluminum Foam
摘要
Forming metal foam is always a challenge for providing the final shape to any component. The present work explores the behavior of a 70% porous aluminum alloy foam. The mechanical deformation of such foams showed their brittle fracture behavior for quasistatic loading conditions. The laser forming of the foam was carried out with process parameter variations in order to minimize surface damage to thin cell walls. The high conductivity of aluminum, along with high porosity, makes the material also challenging for thermal deformation. So, the monitoring of the surface condition of the material becomes an important task for its practical application. The thermal and deformation monitoring was carried out to understand the bending mechanism of such noble materials. In the present material, all the process parameters showed a thermal gradient mechanism (TGM) with local surface temperature reaching near the melting point. A significant difference between the TGM in solid sheets with respect to TGM in foam was observed. It was inferred that the role of material thickness is very prominent in the foam for obtaining different bending mechanisms like thermal gradient, buckling coupling and upsetting. Different characterizations related to microstructure, pore deformation, and densification were used to analyze the bending of the foam.