Application of Laser in Joining Aluminum Foam Hybrid Materials

This article illustrates an experimental campaign aimed at assessing preliminary guidelines for the application of the laser in joining cellular-structured hybrid materials. In particular the target specimens exploited were all characterized by the presence of an aluminum foam core and by an external skin, made in aluminum or in stainless steel. The goal of the present paper is to underline a global feasibility of laser joining of these materials pointing out the role of the main process parameters and to suggest some original techniques which could be adopted in order to improve the overall quality of the joint. The experience described pointed out that, when dealing with this kind of materials, the role of the laser can be dual: in case of high energy density applications it can be used for local fusion of the workpiece, as in traditional welding, while in low energy density ones the radiation can be exploited as a controlled heating source for promoting local thermal actions particularly on the cellular portion of the material.