Research on Laser Cladding Single-Pass Continuous Carbon Fiber-Reinforced Aluminum Matrix Composite Process Based on...

Area of Science:

• Materials Science
• Manufacturing Engineering
• Computational Mechanics

Background:

• Laser cladding of continuous carbon fiber-reinforced aluminum composites (Cf/Al) faces challenges like interfacial stress, fiber degradation, and geometric instability due to rapid thermal gradients.
• Optimizing the laser cladding process is crucial for producing high-performance Cf/Al composites for demanding applications.

Purpose of the Study:

• To develop and validate a computational model for simulating the multi-physics interactions during laser cladding of Cf/Al composites.
• To identify an optimal process parameter window that minimizes thermal distortion and enhances interfacial properties.
• To quantitatively assess the protective role of nickel interlayers against fiber degradation and improve load transfer.

Main Methods:

• A thermoelastic-plastic finite element model with a dual-ellipsoid heat source was developed in Abaqus, incorporating phase-dependent material properties and latent heat effects.
• Simulations were performed for single-track deposition, analyzing transient temperature fields, residual stresses, and interfacial behavior for both uncoated and Ni-coated fiber configurations.
• Experimental validation was conducted to confirm the model's predictive accuracy and assess the performance of Ni-coated Cf/Al composites.

Main Results:

• An optimal laser cladding parameter window (700–800 W laser power, 2 mm/s scan speed, 3 mm spot radius) was identified, reducing thermal distortion to below 5%.
• Nickel interlayers reduced fiber degradation by 42% at 1200 °C and enhanced interfacial load transfer efficiency by 34.7%, lowering matrix tensile stresses to 159 MPa.
• Ni-coated systems demonstrated superior thermal stability (temperature differentials < 12.6 °C) and mechanical interlocking, with interfacial void fractions under 8%.

Conclusions:

• The study establishes a process-structure linkage framework for defect-controlled fabrication of Cf/Al composites.
• The developed finite element model serves as a digital twin methodology for aerospace-grade manufacturing of advanced composites.
• Optimized laser cladding with nickel interlayers significantly enhances the performance and reliability of carbon fiber-reinforced aluminum composites.