Abstract
The paper presents finite element modelling and thermomechanical analysis on the tensile properties of layered aluminium 1050 metal foil parts made by composite metal foil manufacturing. In this paper, a three-dimensional finite element model was developed and validated through experiments to analyse thermal effects on the tensile properties of 200-μm-thick aluminium 1050 metal foils. The effects of thermal stress and strain were studied by carrying out transient thermal analysis on the heated plates used to join the 200-μm-thick metal foils together using a special brazing paste. A standard tensile test at ambient temperature was carried out on the resulting layered dog bone specimens to analyse the thermal effects on the individual layers of metal. The investigations were precisely designed to assess the effect of heat provided amid the brazing operation to join the metal thwarts together as a layered structure and whether it assumed a part in affecting the tensile properties of the final products when contrasted to a solid aluminium 1050 dog bone specimen of the same dimensions. Corrosion testing was also carried out on dog bone specimens made from varying thickness foils (50 μm, 100 μm, and 200 μm) of aluminium 1050 to assess the effect of corrosion on the tensile strength and elongation. The results showed that the specimens did not face the problem of galvanic corrosion of the foil–bond interface. Microstructural analysis was also carried out to analyse the fracture modes of the tested specimens after corrosion testing.
Highlights
Additive manufacturing (AM) technologies have made quite a name for themselves in recent years largely due to their capability to produce complex geometries from computer-aided design (CAD) data
Tensile testing is routinely practiced and does not involve a high number of precautions, but because parts made by composite metal foil manufacturing (CMFM) are composites, it became important to take every factor into account
The Al 1050 specimen made by machining fractured at a load value of 4.483 kN, whereas the parts made by CMFM using 200-μm-thick aluminium 1050 foils fractured at much higher values (S1 = 4.754 kN, S2 = 4.745 kN, and S3 = 4.763 kN)
Summary
Additive manufacturing (AM) technologies have made quite a name for themselves in recent years largely due to their capability to produce complex geometries from computer-aided design (CAD) data. Powder bed and powder feed systems make use of metallic powder These methods have their limitations, especially in terms of the powder cost, and have been widely researched over the years [6,7,8,9]. Residual stress and distortion from excessive heat input, poor accuracy of the part due to the stair stepping effect, and relatively poor surface finish of the final parts are notable These systems require careful monitoring of process parameters such as deposition width, layer thicknesses, wire diameter, wire feed rate, and welding speed to achieve correct part dimensions and surface finish [10,11]. The principles of LOM and brazing were integrated together to form a process that is more “additive” in nature, termed composite metal foil manufacturing (CMFM). 2C.1o.rMroosdieolnlintgesfotirnNguwmaersiccaol nAdnualcytseisd on dog bone specimens made from different thicknesses (50 μm, 100 μm, aBnrdaz2i0n0gμwmas) othfeajlouimniningiummeth10o5d0eHm1p4lo1y/e2dhbayrdCtMemFMpefrofrobilosnodfinalgutmheinmiuemtal1f0o5il0s ttoogaestsheesrs, athnedeffect of cotrhroe spiaosnteobneitnhge ufotiilli–zbedonwdorinketedrfbaectwe.eMenic4r1o0satrnudc4tu70ra°lCa.nAalltyhsoiusgwhaths iasltseomcpaerrraietudreouwtatsoloinwveerstthiganate the fractuthraetmofecthheanmisemltinogf theme ppearrattsumreafdoer balyumCMiniFuMm a(6n6d0 t°hCe),oint elamy awcihthininedthoeuatnonfeaaluinmg itneimumper1a0tu50reblock
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