An Experimental Study on Micro Clinching of Metal Foils with Cutting by Laser Shock Forming
Abstract
:1. Introduction
2. Mechanism of Micro Clinching with Cutting by Laser Shock Forming
3. Experimental Preparation
4. Results and Discussion
4.1. Determination of Process Parameters Based on the Study of Single Layer Material Deformation
4.1.1. Determination of the Number of Laser Pulses
4.1.2. The Matching Relationship between the Total Thickness of Materials and Die Depth
4.2. Feasibility of Micro Clinching with Cutting Process for Joining Similar and Dissimilar Materials
4.2.1. Defects in Micro Clinching with Cutting
4.2.2. Process Window of 1060 Pure Aluminum Foils and Annealed Copper Foils
4.2.3. Joining of Similar and Dissimilar Metal Foils
4.3. Effect of Laser Energy on the Interlock and Minimum Thickness of Upper Foil
4.4. Single Lap Shearing Test
5. Conclusions
- (1)
- Under the single laser pulse, the large interlock could not simply be formed by the increase of laser energy. The use of moderate energy and multiple laser pulses can solve this problem. After a series of experiments, the number of laser pulses was determined to be three pulses.
- (2)
- There is a certain matching relationship between the total thickness of the materials to be connected and the die depth. With the increase of the total thickness of materials, the corresponding die depth that can form a large interlock increases. In addition, the change of the die depth has less influence on the joining of thicker materials. When the total thickness of the materials was in the range of 60–100 μm, the optimum die depth was about two-thirds of the total thickness.
- (3)
- The similar and dissimilar materials could be joined by the micro clinching with cutting process. Seen from the process window of 1060 pure aluminum foils and annealed copper foils, micro clinching with cutting process is more suitable for the material combinations where the upper foil is thicker than the lower foil.
- (4)
- The optimal laser energy for joining the 1060 pure aluminum foils and annealed copper foils (Al/Cu) was in the range of 1200–380 mJ. With the increase of laser energy, the interlock between the metal foils increased while the minimum thickness of the upper foil gradually decreased.
- (5)
- According to the load-displacement curves, it was observed that the maximum load force of Al/Ss combination is about 13.12 N, which is three times larger than that of the Al/Cu combination. The Al/Ss combination with higher shear strength may be due to higher tensile strength of the lower foil or larger interlock and neck thickness of the upper foil. Furthermore, different material combinations had different failure modes.
Acknowledgments
Author Contributions
Conflicts of Interest
References
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Pulse Energy | Energy Stability | Wave Length | Pulse Width | Spot Diameter |
---|---|---|---|---|
80~1800 mJ | <±1% | 1064 nm | 8 ns | 3 mm |
Parameters | Value |
---|---|
Diameter (mm) | 1.3 |
Depth (μm) | 40, 50, 60, 70, 80, 90, 100 |
Corresponding width (μm) | 128, 133, 138, 143, 148, 153, 158 |
Fillet radius (μm) | R1 = 30/R2 = 80 |
Chute angle | 60° |
Parameters | Value |
---|---|
Blank holder force (N) | 12 |
Confinement layer thickness (mm) | 3 |
Ablative layer thickness (μm) | 10 |
Soft punch thickness (μm) | 100 |
The number of laser pulses | 1, 2, 3, 4, 5 |
1060 pure aluminum foils thickness (μm) | 20, 30, 40, 50, 60, 80, 100 |
Annealed copper foils thickness (μm) | 20, 30, 40, 50, 60, 80, 100 |
304 stainless steel foils thickness (μm) | 10, 20, 30 |
Material combinations (upper foils/lower foils) | Cu/Cu; Cu/Ss; Al/Cu; Al/Ss |
Laser Energy (mJ) | 1110 | 1200 | 1290 | 1380 | 1465 | 1550 | 1620 | 1690 | 1745 | 1800 | |
---|---|---|---|---|---|---|---|---|---|---|---|
Materials | Cu/Cu | ▪ | ▪ | ▪ | ▪ | ▪ | ▪ | • | • | • | ▼ |
Al/Cu | ▪ | • | • | • | ▼ | ▼ | ▼ | × | × | × | |
Al/Ss | ▪ | ▪ | ▪ | • | • | • | ▼ | ▼ | ▼ | × |
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Wang, X.; Li, C.; Ma, Y.; Shen, Z.; Sun, X.; Sha, C.; Gao, S.; Li, L.; Liu, H. An Experimental Study on Micro Clinching of Metal Foils with Cutting by Laser Shock Forming. Materials 2016, 9, 571. https://doi.org/10.3390/ma9070571
Wang X, Li C, Ma Y, Shen Z, Sun X, Sha C, Gao S, Li L, Liu H. An Experimental Study on Micro Clinching of Metal Foils with Cutting by Laser Shock Forming. Materials. 2016; 9(7):571. https://doi.org/10.3390/ma9070571
Chicago/Turabian StyleWang, Xiao, Cong Li, Youjuan Ma, Zongbao Shen, Xianqing Sun, Chaofei Sha, Shuai Gao, Liyin Li, and Huixia Liu. 2016. "An Experimental Study on Micro Clinching of Metal Foils with Cutting by Laser Shock Forming" Materials 9, no. 7: 571. https://doi.org/10.3390/ma9070571