Filling of Surface Pores on Aluminum Foam with Aluminum Powder by Selective Laser Melting

Abstract

To improve mechanical properties of a closed-cell type aluminum foam, the surface pores are filled with aluminum powder by selective laser melting (SLM). The relationship between the laser irradiation conditions and solidification characteristics of aluminum powder is investigated with one-line laser irradiation on the aluminum powder with a thickness of 5 mm. The aluminum powder is continuously melted and solidified with laser spot diameter of 0.6 mm and scanning speed of 10–20 mm/s. According to the successful melting and solidification conditions, the SLM is applied to the surface pores of a closed-cell type aluminum foam supplied with aluminum powder. The supplied aluminum powder is confirmed to be successfully melted and welded to the aluminum foam. As the result, the aluminum foam with nonporous surface layer (sandwich structure) is fabricated by the SLM with aluminum powder. The compressive behavior of the fabricated aluminum foam with nonporous surface layer is investigated.