Strength analysis of aluminium foil parts made by composite metal foil manufacturing

Butt, Javaid and Mebrahtu, Habtom and Shirvani, Hassan (2016) Strength analysis of aluminium foil parts made by composite metal foil manufacturing. Progress in Additive Manufacturing, 1 (1-2). pp. 93-103. ISSN 2363-9512 (Submitted)

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Official URL: http://doi.org/10.1007/s40964-016-0008-5

Abstract

A number of different parts for mechanical testing were produced using composite metal foil manufacturing (CMFM). This process is a combination of laminated object manufacturing and brazing technology. Aluminium is one of the toughest metals to join and CMFM can achieve this task with ease. By using aluminium 1050 foils of 0.1 mm thickness, various parts were made according to British and International Standards, including lap joints, peel specimens, dog-bone specimens and tested for their mechanical properties. A special, 80 % zinc and 20 % aluminium by weight, brazing paste was utilized for joining the foils together. The test of the single lap joints show that none of the specimens failed at the bonded area and the failure was always due to fracture of the parent metal. Cohesive failure was also observed for the single lap joints by using 10 mm thick aluminium metal plates. It helped in calculating the lap shear strength which is a useful design parameter. The peel test showed good bond consistency in all the specimens with an average peel strength of 20 MPa. Comparative tensile test was conducted with a dog-bone specimen machined from a solid block of aluminium 1050 and specimens made with CMFM. The results showed that the specimens made by CMFM fracture at force values that are higher than that of the parent metal. This demonstrates that CMFM has the capability to produce high quality and stronger parts as compared to conventional machining methods employed for the production of metal parts. The effect of using different number of layers for the same cross-sectional area has also been investigated.

Item Type: Journal Article
Keywords: Additive manufacturing, Brazing, Laminated object manufacturing, Lap-shear testing, Metal foil, Metal parts, Peel test, Tensile testing
Faculty: Faculty of Science & Technology
Depositing User: Unnamed user with email mohammed.gohrabian@pgr.anglia.ac.uk
Date Deposited: 14 Nov 2016 11:48
Last Modified: 05 Apr 2017 01:02
URI: http://arro.anglia.ac.uk/id/eprint/701116

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