Numerical simulation of laser forming of aluminum sponges: Effect of temperature and heat treatments

Laser forming of open-cell aluminum foams can be modeled by means of 3D thermomechanical models but the correct evaluation of the alloy material properties is a key-factor for obtaining good predictions. In order to increase the model predictability from a quantitative point of view, further information about the material behavior under laser exposure is necessary. In this study the effect of the temperature on the mechanical properties of a commercial aluminum sponge has been evaluated in terms of yielding stress and tangent modulus. Experimental tests have been performed by compression and used to infer mechanical properties by means of a 3D FE model. The same approach has been used also to evaluate the effect of a heat treatment of the sponge on the material behavior during forming. In conclusion numerical simulation of laser heating has been used to show the effect of the laser-material interaction on the final homogeneity of processed foams.