Laser cutting of triangular geometries in aluminum foam: Effect of cut size on thermal stress levels

Laser cutting of triangle shaped geometries in aluminum foam is carried out and the influence of triangle size on temperature and stress fields is examined. ABAQUS finite element code is used to simulate temperature and stress fields in the cut sections in line with the experimental conditions. Laser cut sections are examined incorporating optical and scanning electron microscopes, and energy dispersive spectroscopy. It is found that small size triangle cut results in relatively higher temperatures around the cut edges as compared to large size triangle cut; however, opposite is true for von Mises stress. This is attributed to the slow cooling rate in the case of the small size triangle cuts. Laser cut surfaces are free from large defects and locally scattered small dross attachment are found at the kerf exit.

► von Mises stress is lower for small triangle cut as compared to large triangle cut.
► Contraction and expansion of the cut surface results in high von Mises stress at mid-thickness .
► Laser cut surface is free from large scale defects.
► Small local sideways burning occurs at the cut edges.
► The small scale dross attachment is observed at the kerf exit.