Abstract Al-SiC metal matrix composites (MMCs) are promising materials for aerospace and electronic packaging applications. However, machining of Al-SiC MMC is very challenging, often resulting in surface scratches by the hard SiC particles and extensive tool wear. Recent approaches of laser assisted machining using low cutting speeds and low laser power densities, although reduce the tool wear, lead to overheating of the bulk material and their irreversible thermal deformation. Here we report a new approach of high speed and high-power density laser-assisted turning (LAT) of an Al-SiC MMC (Al2124 + 17 vol% 0.3 μm SiC). The high cutting speed allows the surface of the locally heated parts to be removed timely avoiding the excessive heat transfer from the surface layer to the main body, which also greatly improves the productivity. The diameter of the laser beam spot (0.7 mm) is smaller than the nose radius of the turning insert (0.8 mm) so that the heat generated from the laser radiation can be effectively removed by the chips. As a result, overheating of the entire part is avoided. The maximum laser power density in this work is 3.38 × 106 W/cm2, which is two orders of magnitude higher than that reported in previous LAT publications. A cutting speed of 565 m/min can be achieved leading to over 2.7–140 times increase in productivity compared with previously reported values, and the surface quality has also been substantially improved in addition to reduced tool wear.

中文翻译：

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高速、高功率密度激光辅助加工 Al-SiC 金属基复合材料，显着提高生产率和表面质量

摘要 Al-SiC 金属基复合材料 (MMC) 是航空航天和电子封装应用的有前途的材料。然而，Al-SiC MMC 的加工非常具有挑战性，通常会导致硬质 SiC 颗粒的表面划伤和大量刀具磨损。最近使用低切割速度和低激光功率密度的激光辅助加工方法虽然减少了工具磨损，但会导致大块材料过热及其不可逆的热变形。在这里，我们报告了一种 Al-SiC MMC（Al2124 + 17 vol% 0.3 μm SiC）的高速和高功率密度激光辅助车削 (LAT) 的新方法。高切削速度使局部受热零件的表面得到及时去除，避免了从表面层到主体的过多热量传递，这也大大提高了生产率。激光束光斑的直径 (0.7 mm) 小于车削刀片的刀尖半径 (0.8 mm)，因此切屑可以有效地去除激光辐射产生的热量。结果，避免了整个部件的过热。这项工作中的最大激光功率密度为 3.38 × 106 W/cm2，比之前 LAT 出版物中报道的高两个数量级。与之前报道的值相比，可以实现 565 m/min 的切削速度，从而使生产率提高 2.7-140 倍以上，除了减少刀具磨损外，表面质量也得到了显着改善。避免了整个零件的过热。这项工作中的最大激光功率密度为 3.38 × 106 W/cm2，比之前 LAT 出版物中报道的高两个数量级。与之前报道的值相比，可以实现 565 m/min 的切削速度，从而使生产率提高 2.7-140 倍以上，除了减少刀具磨损外，表面质量也得到了显着改善。避免了整个零件的过热。这项工作中的最大激光功率密度为 3.38 × 106 W/cm2，比之前 LAT 出版物中报道的高两个数量级。与之前报道的值相比，可以实现 565 m/min 的切削速度，从而使生产率提高 2.7-140 倍以上，除了减少刀具磨损外，表面质量也得到了显着改善。