Laser foaming for joining aluminum foam cores inside a hollow profile

This paper investigates the feasibility of the joining process of two aluminum foam cores contained in a tubular profile exploiting laser foaming of a solid precursor. The aim is to examine the foaming process by means of external laser irradiation of a hollow steel profile, which contains two separated aluminum foam cores intermingled by a foamable solid aluminum precursor. The experimental activity showed that three process parameters should be taken into account in order to obtain a sound foam: interaction time, laser beam power density and total amount of beam energy delivered to the work-piece. A numerical simulation allowed the qualitative evaluation of the temperature field inside the solid precursor with the purpose of better understanding the effect of the chosen parameters on the process itself.

► This paper deals with experimental and simulation activities concerning laser foaming of aluminium solid precursors.
► The role of process parameters on the foam formation and developments is investigated.
► A simulation campaign allowed to understand and characterize the thermal field occurring into the specimen during the process.
► The foaming of the solid precursor is used for joining together two foam cores positioned inside a hollow profile.
► Feasibility diagrams for the process were assessed.