Surface Morphology and Kerf Quality During Fiber Laser Cutting of High Volume Fraction SiC Particles-Reinforced Aluminum Matrix Composites

Due to the high hardness and wear resistance of SiC particles, severe tool wear was prevalent when cutting SiC particles-reinforced aluminum matrix (SiCp/Al) composites with traditional machining methods. This paper aims to comprehensively investigate the feasibility of laser cutting SiCp/Al composites with high volume fraction of SiC particles under different processing parameters. Surface morphology and cross-section characteristics were analyzed for further understanding laser–SiCp/Al composite interaction/removal mechanisms. Results showed that high specific energy was the most significant factor affecting surface quality during laser cutting SiCp/Al composites, and the threshold value was ~ 90 J/mm for successfully cutting through 1.0-mm-thick samples and ~ 450 J/mm for 5.0-mm-thick ones. Stripes, re-solidified materials, dross and spatters were typical defects observed during high-power fiber laser cutting SiCp/Al composites with high volume fraction. The experimental results can most likely bring new knowledge to understand the characteristics of thermal defect and heat conduction following high-efficient fiber laser cutting SiCp/Al composites and also provide data for applying high-power fiber laser in advanced automotive/aerospace industry for future applications.