Abstract
Aluminum of cylindrical profile (of diameter 1–4 mm) was trailed by laser metal wire deposition for potential riveting applications. The rivet was built onto a Ti6Al4V substrate through a hole in an AA6061 sheet. The built feature was postprocessed by a high-frequency laser washing technique to obtain the desired finish. Parameter optimization has allowed increased productivity by almost seven times while achieving required wetting conditions and metallurgical properties. It is found that the quality (both morphology and metallurgy) of the laser rivet joint is highly dependent on the laser wash parameters. The rivet crown and welding areas improved by the postwash process were directly reflected in the microhardness and shear tests and increased by 90% and 62%, respectively, compared with those in an unwashed rivet.
Highlights
In the aerospace and automotive sectors, lightweight structures are increasingly needed to reduce material use and energy costs
The laser metal wire deposition (LMWD) system was based on (1) the wire feeding device with the wire nozzle being kept at 30° feeding angle to the substrate surface; (2) for the optical condition, the focus lens is 100 mm and the collimator is 200 mm, and the fiber diameter is 0.05 mm; (3) the laser head mounted on the motion system controlled by a computer numerical control (CNC)-system with the processing route predefined by programming; (4) the trailing shielding device, using argon to protect the titanium welding pool from the oxidation and contamination
Depending on the influence of the thermal history and phase transformation in scitation.org/journal/jla the process, the cross section is divided into three basic microstructure zones: the base material (BM), the heat-affected zone (HAZ), and the fusion zone (FZ) with added material (AM)
Summary
In the aerospace and automotive sectors, lightweight structures are increasingly needed to reduce material use and energy costs. A laser metal wire cylinder deposition (LMWCD) process was developed as a feasibility study to deposit a cylindrical feature in a minor scale, and three optimized methods [i.e., normal, high speed (HS), and continuous spiral (CS)] were investigated in a parametric study. The LMWD system was based on (1) the wire feeding device (driving unit and tube) with the wire nozzle being kept at 30° feeding angle to the substrate surface; (2) for the optical condition, the focus lens is 100 mm and the collimator is 200 mm, and the fiber diameter is 0.05 mm; (3) the laser head mounted on the motion system controlled by a computer numerical control (CNC)-system with the processing route predefined by programming; (4) the trailing shielding device, using argon (gas flow at 25 l/min) to protect the titanium welding pool from the oxidation and contamination
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