Papers by Author: Giuseppe Casalino

Abstract: The new generation of high power fiber lasers presents several benefits for industrial application. Nevertheless, due to the small spot size of the laser, the fiber laser has difficulties in some welding applications. These shortcomings can be overcome by laser-arc hybrid welding technique such as laser-gas metal arc welding or laser-gas tungsten arc welding. In this work, a high power fiber laser was coupled to an arc welder and the AA5754-H111 magnesium aluminum alloy was welded. The trials were carried out using laser leading configuration. A new generation of high power fiber laser was used. The experimental trials included process parameters such as laser power, welding speed and arc current. Microstructure, microhardness and weld appearance were analyzed. The experimental results showed that laser leading configuration produces full penetration for some welding parameters. The obtained results worth a larger investigation based on the experimental design technique.

Abstract: Laser ablation is a new, very flexible process for micro-fabrication of micro-moulds and other micro-system devices. This process is suitable for machining difficult-to-machine materials, like ceramics, dielectrics, carbide and hardened steel with excellent productivity and surface. The paper presents the investigation on the material removal rate of aluminium 5754 using a nanosecond Nd:YAG laser with a wavelength of 1064 nm.

Abstract: The design of experiments (DOE) is a very useful tool to design and analyze complicated industrial design problems. They help to understand the variability a manufacturing process by investigating which parameters and their interaction mainly affect the output repeatability. As a consequence, it enables to individuate the combination of parameters that optimize the output avoiding misinterpretation that can be due to the singularity of the experimental data. In this study the factorial analysis was used to investigate the effects of the major geometrical parameters on the shape of the force-displacement curve of the self piercing riveting (SPR) process. A full two level three-factorial design (23) was completed, three-way interaction was not considered. The statistical analysis was carried out at four different points of the force-rivet displacement curve. These points can be considered critical since they limit the four steps in which the process is commonly divided for studying purpose. The experimental data did not fulfil the required design points, the missing points were obtained by a finite element model of the riveting process, which furnished the force versus the rivet run.

Abstract: Direct Laser Metal Deposition (DLMD) is actually one of the most attractive techniques in the group of Material Accretion Manufacturing (MAM) processes. In fact, the DLMD technology is able to realize, to repair and restore, objects, moulds and tools, directly from the 3D CAD model in a rapid and economic way. A great variety of metals, including those very difficult to work with the conventional techniques, can be shaped in a large number of complex geometries. This technique is also well suited to produce very hard coatings. The metallic parts, which are obtained through melting coaxially fed powders with a laser, present very good mechanical properties, with minimum porosity and good adhesion to the substrate. The objective of this work was to optimise the scanning velocity of the laser beam in order to maximize the density of DLMD parts. The optimization procedure was worked out with a mathematical model together with an experimental analysis to study the shape of the track clad generated melting coaxially fed powders with a laser. The material tested was Colmonoy 227-F, a nickel alloy specially designed for manufacturing moulds. The presented methodology has permitted to select the better combination of parameters that produce almost full density parts, free of cracks and well bonded to the substrate sintered parts.

Abstract: The residual stress in steel welding can highly influences the performance of the joint during its working life. Both boundary conditions and metal phase transformations have influence on the levels of the residual stress in the weld. In this paper the residual stress for AISI 4047 bead-on-plate samples were measured by strain gage method after laser welding with different values for the laser speed and power, and focus height. The laser used for this project was the ROFIN DC 015 Industrial CO2 Slab Laser. This laser, registered as class 4 laser product in accordance with the European Norm EN 60825 is an high frequency excited, diffusion cooled C02 gas laser, designed to be used for processing materials in a industrial environment. The measurement procedure was performed on all the welded specimens taking notes of 3 strains (ε1 ε2 ε3) relative to as many gages at different depths, following the American Society for Testing Materials (ASTM) standard. Thereafter the residual stresses were calculated by means of a non-linear finite element analysis. The analysis took in account the thermo-mechanical phenomena with temperature dependent steel properties. The other considered also the phase transformation and phase-dependent thermal and mechanical properties.