Laser polishing of aluminum by remelting with high energy pulses

Laser polishing is a contact‐free, quick and automated method to smooth surfaces. The method has been applied to different forging and casting aluminum alloys. The surfaces of the samples were belt‐grinded with a grain size of mesh 240. The samples are protected from ambient air in a gas shield chamber. The used laser system is an Nd : YAG Laser with maximum pulse energy of 65 J. The initial and the laser polished surfaces have been analyzed by microscopy, roughness spectroscopy, white light interferometry and cross‐section polishes. The surfaces of the laser polished forging alloys are covered by multiple lateral and horizontal cracks. Unlike the forging alloys, the casting alloys could be processed well by laser polishing. The initial surface roughness of Ra 240  = 1.37 µm was reduced up to Ra LP  ≈ 0.47 µm. This represents a roughness reduction of 66%. The roughness spectroscopy of the laser polished surface shows for structural wavelengths from 2.5 µm to 500 µm a Ra‐value close to 0.1 µm and from 500 µm to 800 µm higher values. The remelted area extends up to100 µm into the material.