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RESEARCH PAPER

Evolution behavior of laser welding in hybrid structure between open-cell aluminum foam and solid aluminum shell Paiboon Wattanapornphan 1 & Chakkrist Phongphisutthinan 1

&

Tetsuo Suga 2 & Masami Mizutani 2 & Seiji Katayama 2

Received: 5 October 2018 / Accepted: 23 October 2020 # International Institute of Welding 2020

Abstract Hybrid structure between porous core and solid shell can combine lightweight open-cell structure of porous materials with good strength of solid shell. Laser welding is considered as an effective process to join porous metal with solid metallic shell. In this study, the evolution behavior of laser welding by a continuous wave (CW) disk laser welding between open-cell aluminum alloy (cast AC2A alloy) and aluminum sheet (wrought AA6063 alloy) was investigated. X-ray transmission system and a high-speed camera were performed during laser welding to investigate the dynamic keyhole, porosity formation, plasma plume, and spatter formation. Laser keyhole became unstable during entering and passing the vacancies of porous aluminum, which consequently resulted in bubble formation in the molten pool. Keywords Open-cell aluminum . Porous aluminum . Laser welding . Dynamic keyhole

1 Introduction Manufacturing process of porous aluminum or aluminum foam has been developed in the last decades. The properties of aluminum foam have been continuously improved and have been applied in various products such as automotive parts and construction parts. The porous structure can absorb energies such as vibration and noise as well as provide insulation against heat and electromagnetic waves. Porous aluminum was generally classified into 2 groups by porous structures: open-cell structure and closed-cell structure. In the open-cell structure, each pore is interconnected with the neighbor pores. In contrary, the pore in closed-cell structure is Recommended for publication by Commission XII - Arc Welding Processes and Production Systems Supplementary Information The online version contains supplementary material available at https://doi.org/10.1007/s40194-02001022-x. * Chakkrist Phongphisutthinan [email protected] 1

National Metal and Materials Technology Center, National Science and Technology Development Agency, Rangsit, Pathum Thani 12120, Thailand

2

Joining and Welding Research Institute, Osaka University, 11-1 Mihogaoka, Ibaraki, Osaka 567-004, Japan

separated from the neighbor pores. The porous aluminum can be produced by various manufacturing processes. Major metallic foams production methods include metallic deposition and sputter deposition process [1], powder metallurgy (blowing agent) [2], and casting (pressure infiltration process) [3]. The mechanical properties of open-cell aluminum depend significantly on the pore structure, the density, and the thickness of cell walls [4]. Comparing with the solid aluminum, porous aluminum has higher strength-to-weight ratio, depending on the porous structures and alloy compositions. The maximal aluminum open-cell board produced by pressure inf