Factorial Analysis of Fiber Laser Fusion Cutting of AISI 304 Stainless Steel: Evaluation of Effects on Process Performance, Kerf Geometry and Cut Edge Roughness

Factorial Design-of-Experiment analyses were applied for conventional and beam oscillation fiber laser cutting of 10 mm thick AISI 304 stainless steel. Considered factors in case of the conventional process with a static beam involve both laser and cutting gas parameters, in particular the laser power, the focal plane position, the cutting gas pressure, the nozzle stand-off distance as well as the nozzle diameter. The conducted trials were evaluated with respect to the achievable cutting speed, the cut kerf geometry and the cut edge roughness. Noticeable correlations between cut edge roughness and cut kerf geometry stimulated the development of a corresponding Computational Fluid Dynamics (CFD) model of the cutting gas flow through the kerf. A specific approach of data synchronization revealed that the experimentally determined roughness values do well correlate with numerically computed values of the backward directed component of the gas-induced shear stress and that the cut kerf geometry as internal process-inherent boundary condition influences relevant cutting characteristics more than controllable external cutting gas parameters. Finally, effects of circular beam oscillation were investigated by an additional factorial analysis considering the laser power, the focal plane position, the oscillation frequency and the oscillation amplitude as factors. The results demonstrate the potential of beam oscillation techniques for quality improvements in laser cutting.

Introducing Fractal Dimension for Interlaminar Shear and Tensile Strength Assessment of Mechanically Interlocked Polymer-Metal Interfaces

The interlaminar strength of mechanically interlocked polymer–metal interfaces is strongly dependent on the surface structure of the metal component. Therefore, this contribution assesses the suitability of the fractal dimension for quantification of the surface structure, as well as interlaminar strength prediction of aluminum/polyamide 6 polymer–metal hybrids. Seven different surface structures, manufactured by mechanical blasting, combined mechanical blasting and etching, thermal spraying, and laser ablation, are investigated. The experiments are carried out on a butt-bonded hollow cylinder testing method that allows shear and tensile strength determination with one specific specimen geometry. The fractal dimension of the metal surfaces is derived from cross-sectional images. For comparison, the surface roughness slope is determined and related to the interlaminar strength. Finally, a fracture analysis is conducted. For the investigated material combination, the experimental results indicate that the fractal dimension is an appropriate measure for predicting the interlaminar strength.

Effect of Metal Surface Topography on the Interlaminar Shear and Tensile Strength of Aluminum/Polyamide 6 Polymer-Metal-Hybrids

Mechanical interlocking has been proven to be an effective bonding mechanism for dissimilar material groups like polymers and metals. Therefore, this contribution assesses several surface pretreatments for the metallic adherent. Blasting, etching, combined blasting and etching, thermal spraying, and laser structuring processes are investigated with regard to the achievable interlaminar strength and the corresponding surface roughness parameters. The experiments are carried out on EN AW-6082/polyamide 6 polymer-metal-hybrids, utilizing a novel butt-bonded hollow cylinder specimen geometry for determining the shear and tensile strength. The experimental results indicate that the surface roughness slope has a major impact on the interlaminar strength. A laser-generated pin structure is found to provide the best mechanical performance as well as the highest surface slope of all investigated structuring methods.