Laser forming of glass laminate aluminium reinforced epoxy (glare): on the role of mechanical, physical and chemical interactions in the multi-layers material

The present work concerns the laser forming of Fiber-Metal Laminates (FMLs) by a high power diode laser source. FMLs are made of different layers of metal and composite material. The wide difference in the thermo-mechanical and physical properties of the different layers within FMLs makes them extremely problematic to be reprocessed. In particular, the economic shaping of FMLs in complex shapes is practically impossible, limiting greatly their field of application. Therefore, this manuscript explores the possibility of using laser forming to reprocess FMLs and obtain final components with precisely controlled bending radii. For this purpose, the effect of the laser operating parameters, namely laser power, scanning speed and number of passes, on the final shapes of FMLs was investigated. Secondly, further tests were also performed to obtain other complex shapes on FMLs from multiple laser scanning paths, side by side and equidistant on the substrates. An analysis of the failure of the substrates during the shaping process was also performed, with particular emphasis on deformation mechanisms, interfacial delamination and thermal alteration of the layers. The experimental results showed the good viability of laser reprocessing to shape FMLs, thus opening up new possible applications of this class of materials in aeronautical and aerospace applications.