International Journal of Adhesion and Adhesives 85 (2018) 184–192

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International Journal of Adhesion and Adhesives

journal homepage: www.elsevier.com/locate/ijadhadh

Suppression of shrinkage porosity in laser-joining of CFRP and steel using a T

laser surface modification process “Surfi-Sculpt ®”
⁎
Zhou Zhanga, Xiang-Hu Tanc, Jing Zhangd, Ji-Guo Shanb,
a
Guangdong Provincial Key Laboratory of Advanced Welding Technology, Guangdong Welding Institute (China-Ukraine E.O.Paton Institute of Welding), Guangzhou,
Guangdong Province 510650, China
b
Department of Mechanical Engineering, Tsinghua University, Beijing 100084, China
c
Beijing Hainachuan Automotive Parts Co., Ltd., Beijing 100021, China
d
IPG (Beijing) Fiber Laser Technology Co., Ltd., Shanghai 201702, China

A R T I C LE I N FO A B S T R A C T

Keywords: The emergence of shrinkage porosity is a significant issue in the laser joining of carbon fiber reinforced polymer
A: Polymer–matrix composites (PMCs) (CFRP) and steel. The joining process uses laser heating to melt a thermoplastic CFRP matrix in contact with a
B: Porosity metal substrate to create a physical bond upon cooling. During the cooling process, melted CFRP at different
C: Finite element analysis (FEA) location has different solidification rate, leading to the shrinkage porosity in the CFRP. In this study, the laser
D: Mechanical testing
Surfi-Sculpt® is used to prevent the formation of shrinkage porosity in CFRP. The effects of the morphology
E: Joints/joining
characteristics (protrusion height and density) on shrinkage porosity are investigated, and the thermal dis-
tribution and history during the joining is simulated to examine mechanism of shrinkage porosity suppression.
The results show that formation of shrinkage porosity can be suppressed with the laser Surfi-Sculpt®, which is
attributed to the change of heat conduction path. The protrusions conduct the heat from the interior of melted
zone to steel, decreasing the heat accumulation at the interface and suppressing the formation of shrinkage
porosity. After adopting this technique, the porosity can be reduced from 7.13% to 1.26% and the shear strength
of the joint increases from 9.3 MPa to 30.8 MPa.

1. Introduction
Carbon fiber reinforced polymer (CFRP) attracts more and more
attention due to its high specific strength and excellent fatigue re-
sistance [1]. It is inevitable to join CFRP to metal when fabricating the
integrated structures and components with low weight and high
strength in the aircraft construction and automobile industries [2,3].
Laser joining CFRP and metal is an advanced technique which has many
advantages over the conventional joining methods such as adhesive
bonding or mechanical fastening [4–10]. Since the CFRP is directly
joined to metal without additive, laser joining can avoid the drawbacks
related to adhesive bonding process such as long processing period,
poor resistance to damp-heat and the emission of volatile organic
compounds [11–15]. Extra bolts or rivets are used to join CFRP to metal
in the mechanical fastening technologies, which results in adding extra
weight to the original structure and dissatisfies the need of lightweight
design in contemporary industrial manufacturing [16]. Meanwhile, the
holes introduced by the bolts or rivets are detrimental to the final
strength of the dissimilar joint because of the stress concentration
[17,18]. Compared to the mechanical fastening technologies, laser
joining can reduce weight of the hybrid structure and increase effi-
ciency [19,20]. However, laser heat causes thermal damage of CFRP
during laser joining process, which deteriorates the mechanical prop-
erties of the joint. According to the existing research, during the laser
joining of CFRP and metal, porosities in different sizes and numbers are
always generated in the melted zone of CFRP [21]. The porosity in
CFRP/metal laser joint reduces the effective loading area and causes
stress concentration. Consequently, the joint fails at the porosity zone
rather than the bonding interface of CFRP/metal [7,21]. So the gen-
eration of porosity in CFRP during laser joining becomes a critical issue
restricting improvement in mechanical properties of the CFRP/metal
laser joint.
Shan, Katayama, Markovits and Nagatsuka [7,9,13,21–24] in-
vestigated the characteristic and formation mechanism of the porosity.
There are two types of porosity in CFRP: (1) The pore distributing near
the bonding interface is caused by the pyrolysis of CFRP as a result of
high interface temperature [7,21,22]; (2) The porosity distributes far
away from the bonding interface is the shrinkage porosity caused by the
non-uniform solidification of CFRP near the bonding area. During the
laser joining process, the heat is quickly conducted by steel, and the

⁎
Corresponding author.
E-mail address: shanjg@mail.tsinghua.edu.cn (J.-G. Shan).

https://doi.org/10.1016/j.ijadhadh.2018.06.013
Accepted 6 June 2018
Available online 14 June 2018
0143-7496/ © 2018 Elsevier Ltd. All rights reserved.
Z. Zhang et al.
Fig. 1. Schematic diagram of laser Surfi-Sculpt® process.
CFRP close to bonding interface solidifies first because steel has higher
thermal conductivity than CFRP, which leads to the formation of
shrinkage porosity in the final solidification region [9]. The pores can
be completely eliminated by strict control of heat input. However, there
is no effective solution to suppress the shrinkage porosity. To further
improve the joint performance, the research on how to prevent the
shrinkage porosity is in urgent need.
According to the existing research [9], the solidification behavior of
the melted zone is crucial to shrinkage porosity formation. In this
paper, in order to suppress its formation, laser Surfi-Sculpt® process is
introduced to create protrusions on the surface of steel. We applied the
laser Surfi-Sculpt® [25] on the mild metal to develop protrusions on the
surface of steel sheet. The protrusions can change solidification process
of melted CFRP in the lap joint of CFRP and steel, thus promoting so-
lidification of melted CFRP during laser joining of steel and CFRP and
suppressing the shrinkage porosities. The effects of morphology
Fig. 2. Schematic diagram of laser joining between CFRP and steel.
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International Journal of Adhesion and Adhesives 85 (2018) 184–192
Fig. 3. Cross-section of CFRP/steel joint without laser Surfi-Sculpt®.
characteristic parameters, i.e., protrusion height and protrusion den-
sity, on shrinkage porosities are investigated. And the effect of pro-
trusion on thermal history and distribution of melted CFRP is in-
vestigated by finite element simulation.
2. Experimental procedures
2.1. Laser Surfi-Sculpt®
In this research, laser Surfi-Sculpt® [25–29] is applied to create a
customized textured surface on the steel before the joining process. The
laser beam directly radiates on workpiece surface. After generation of a
molten pool, it is then rapidly moved relative to the workpiece. As a
result of vapour pressure and surface tension effects, the material is
moved from the pool to the region at the end of the beam movement
[30,31]. By repeating this process, it is possible to build up protrusions
above the surface of the workpiece, as schematically shown in Fig. 1.
This laser Surfi-Sculpt® process is carried out using an IPG YLS-2000
fibre laser (wavelength: 1060 nm, focal length: 200 mm, focal spot
Z. Zhang et al. International Journal of Adhesion and Adhesives 85 (2018) 184–192

Fig. 4. Cross-sections of CFRP/steel joints of different sections with laser Surfi-Sculpt® under different protrusion average heights: (a) 0.09 mm (b) 0.12 mm (c)
0.15 mm (d) 0.22 mm (e) 0.31 mm (protrusion density of 1.25 /mm2).

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Fig. 5. Summary statistics of the porosity content as a function of protrusion
average height (protrusion density of 1.25 /mm2).
diameter: 0.13 mm). The chemical composition of mild steel is 0.006 C,
0.2 Mn, 0.025 P, 0.02 S, 0.015 Al, 0.03 Ti, and balance Fe (in wt%). The
specimen dimensions of mild steel are 40 mm × 30 mm × 1.2 mm. To
study the influence of the protrusion height on shrinkage porosities, we
keep the laser power of 400 W, the scanning speed of 24 m/min, the
scanning length of 1.6 mm, the protrusions spacing of 0.4 mm and the
protrusion density of 1.25 /mm2. It should be noted that the protrusion
density is defined as the ratio of the protrusion number and the pro-
cessing area of the steel. The protrusions with different heights are
obtained by changing the scanning repeating times. The approximate
width of the protrusions and the intrusions is 0.2 mm. The approximate
length of the protrusions is 1.1 mm while that of intrusions is 0.5 mm.
2.2. Laser joining
Fig. 2 shows the experimental setup for laser joining process of
CFRP and steel with laser Surfi-Sculpt®. Laser joining is carried out
under the power of 700 W, scanning speed of 12 mm/s and defocusing
distance of 110 mm. Argon gas is supplied at a flow rate of 25 L/min as
shielding gas in both front side and back side. The steel is pressed on the
CFRP plate by a specially-designed fixture with four bolts to keep a tight
contact, and an 80 N*cm torque is equally applied to each bolt. The 3-
mm-thick CFRP panel with a polyamide resin matrix (PA6T) is re-
inforced by 30 vol% chopped polyacrylonitrile (PAN) carbon fibers. The
dimensions of the mild steel specimen and the CFRP specimen are
40 mm × 35 mm and 28 mm × 17 mm respectively. The glass transi-
tion temperature of CFRP is ~110 °C and the melting temperature is
303 °C [21]. Before joining, CFRP panels are dried in an oven for more
than 24 hours. After laser joining, the cross-sections of the joint are cut
perpendicular to the joining direction at the protrusion position (A-A
section), the intrusion position (C-C section) and the position in be-
tween (B-B section), as shown in Fig. 2. Olympus BX51M/DP72 me-
tallographic microscope is used to characterize the CFRP/steel inter-
face. The pixel value of the porosity is acquired by image processing
based on MATLAB software, and the relative content of the shrinkage
porosities is calculated by dividing the pixel value of the porosity by
that of the image.
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International Journal of Adhesion and Adhesives 85 (2018) 184–192
2.3. Finite element simulation
A three-dimensional finite element model with the cylindrical pro-
trusions and intrusions is developed to simulate the temperature field of
the laser joining process for the lap joint of CFRP and mild steel. The
simulations are carried out using ABAQUS version 6.10.1. The meshes
are generated by ABAQUS CAE. The aim of the simulations is to in-
vestigate the effect of protrusion on thermal history and distribution of
melted CFRP and further analyze the experiment results.
During laser joining, the governing laser thermal equation is given
by:
3Q −3(x 2 + y 2 ) ⎤
q (x , y ) = exp ⎡
πr 2 ⎢
⎣ r2 ⎥
⎦ (1)
Where r is the radial distance, Q is the laser power.
3. Results and discussion
The cross-section of CFRP/steel joints without and with laser Surfi-
Sculpt® are shown in Figs. 3 and 4 respectively. As shown in Fig. 3, a
large amount of shrinkage porosities with micron size can be observed
in CFRP. The shrinkage porosities are distributed near the bottom of
melted zone, at a distance from the bonding interface. The relationship
between the variation of shrinkage porosity content and the average
height of the protrusion is shown in Fig. 5. It can be observed that, the
laser Surfi-Sculpt® process can effectively reduce the average porosity,
from 7.13% to 1.26%. Porosity at different sections of the joint (A-A
section, B-B section and C-C section) shows the same tendency with
varied protrusion height, that is, the porosity first decreases and then
increases with increasing protrusion average height. When the protru-
sion average height lies in the range of 0.14–0.22 mm, the average
porosity varies around 3.75–7.13%. Also note that the average porosity
has the minimum value of 1.26% with the protrusion average height of
0.22 mm.
If the protrusion average height is fixed to be 0.22 mm, different
protrusions densities can be obtained by adjusting the protrusions
spacing. Fig. 6 shows the cross-sections of CFRP/steel joints with dif-
ferent protrusion densities and Fig. 7 shows the effects of protrusion
density on porosity. With the increase of protrusion density, porosity
first decreases, and then increases after reaching minimum value at
medium protrusion density. The porosity can be reduced from 7.13% to
1.26% under optimized protrusion density.
Shrinkage porosity is formed because of insufficient feeding of
molten CFRP for the areas solidifying at last stage. The temperature
fields are examined to predict the shrinkage porosity. Fig. 8 shows the
thermal distribution of CFRP/steel joint without laser Surfi-Sculpt®
during different solidification stages. The grey in temperature field
means that the temperature is higher than the melting point of CFRP,
303 °C [21]. The cross-section of CFRP/steel joints is symmetrical, thus
only the left half of temperature field is displayed. Schematic diagram
of heat conduction of CFRP/steel joints without laser Surfi-Sculpt® is
shown in Fig. 9a. During solidification stage, heat is quickly conducted
by steel because of its higher thermal conductivity than CFRP, so CFRP
close to the bonding interface solidifies first and CFRP near the bottom
of the melted zone solidifies last. Consequently the capillary with a
narrow feeding path or the hot spot is formed at time t0, t0 + 78 ms and
t0 + 156 ms, as shown in Fig. 8. For the capillary feeding, the me-
chanism of solidification feeding can be expressed by the Poiseuille
Z. Zhang et al. International Journal of Adhesion and Adhesives 85 (2018) 184–192

Fig. 6. Cross-sections of CFRP/steel joints of different sections with laser Surfi-Sculpt® under different protrusion densities: (a) 1.67 /mm2 (b) 1.43 /mm2 (c) 1.11
/mm2 (d) 0.91 /mm2 (e) 0.77 /mm2 (protrusion average height 0.22 mm).

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equation [32]:
dP 8vη
=
dx πR 4 (2)

Where is the pressure gradient, v is the volume flowing per second, η

Fig. 7. Summary statistics of the porosity content as a function of protrusion
density (protrusion average height 0.22 mm).
dP
dx
is the viscosity, and R is the radius of the capillary. It is clear without
going further that the resistance to flow is dependent on the size of
capillary (R). R is very small at the corner of the capillary (Fig. 8),
making the feeding very difficult and leading to the formation of
shrinkage porosities at this location. As solidification goes on, shrinkage
porosities are formed along the bottom of the melted zone (Fig. 3).
However, the heat conduction of CFRP/steel joints with laser Surfi-
Sculpt® is different (Fig. 9b). The heat inside melted zone can be con-
ducted by the protrusions, which accelerates the solidification of CFRP
near the bottom of the melted zone. The thermal distribution at dif-
ferent sections A-A, B-B and C-C of CFRP/steel joint during different
solidification stages are shown in Figs. 10–12 respectively. From the
thermal distribution of all three sections, it can be observed that the
melted CFRP gradually solidifies from the bottom of melted zone to
bonding interface, and no capillary is formed at the bottom of melted

Fig. 8. Thermal distribution of the CFRP/steel joint without laser Surfi-Sculpt® during different solidification stages.

Fig. 9. Schematic diagrams of heat conduction of CFRP/steel joints (a) without laser Surfi-Sculpt® and (b) with laser Surfi-Sculpt®.

Fig. 10. Temperature field of A-A section of the CFRP/steel joint during solidification at t0, t0 + 204 ms and t0 + 306 ms (protrusion average height 0.22 mm and
protrusion density 1.25 /mm2).

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Fig. 11. Temperature field of B-B section of the CFRP/steel joint during solidification at t0, t0 + 142 ms and t0 + 284 ms (protrusion average height 0.22 mm and
protrusion density 1.25 /mm2).

Fig. 12. Temperature field of C-C section of the CFRP/steel joint during solidification at t0, t0 + 102 ms and t0 + 244 ms (protrusion average height 0.22 mm and
protrusion density 1.25 /mm2).

Fig. 13. Temperature field under the protrusion average height of (a) 0.14 mm and (b) 0.38 mm (protrusion density of 1.25 /mm2).

Fig. 14. Temperature field under the protrusion density of (a) 1.67 /mm2and (b) 0.77 /mm2 (protrusion average height of 0.22 mm).

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Fig. 15. Shear force and shear strength of the joints with laser Surfi-Sculpt®
(protrusion average height 0.22 mm and protrusion density 1.25 /mm2) or
without laser Surfi-Sculpt®.
zone. So laser Surfi-Sculpt® can promote the solidification of CFRP at
that area. However, hot spots still form at the central area of the melted
zone. It means that the shrinkage porosities are easy to form in this
area, this agrees with the phenomena we observed in Fig. 4d.
Both protrusion average height and protrusion density affect the
heat conduction, thus affecting the formation of shrinkage porosity. As
shown in Fig. 13a, if the height of protrusion is too low, the heat at the
bottom of the melted zone is unable to be conducted by the protrusions
and the capillary is formed. If it is too high, the heat conduction path
gets longer and the heat conduction ability declines. The hot spot is
easily formed at top of the protrusion (Fig. 13b). So too low or too high
protrusion tends to increase the shrinkage porosity (Fig. 5). The pro-
trusion density affects the porosity in a similar way. If the protrusion
density is too high, capillary is formed near top of the protrusions
(Fig. 14a). If it is too low, capillary or hot spot are formed between the
protrusions (Fig. 14b). This agrees with the porosity change in Fig. 7.
The shear strength of mild steel/CFRP joints with laser Surfi-Sculpt®
or without laser Surfi-Sculpt® is investigated. The selected joint with
Surfi-Sculpt® pretreatment has the lowest porosity (average height of
the protrusions: 0.22 mm; density of the protrusions: 1.25 /mm2). Five
samples with the same parameters are tested, and the representative
curves of the tensile shear are shown in Fig. 15. The results show that
the shear force of the joint with laser Surfi-Sculpt® increases from
1118.7 N to 3136.7 N and the shear strength increases from 9.3 MPa to
30.8 MPa when compared with the joint without laser Surfi-Sculpt®. It
is speculated that fewer porosity in the CFRP reduces the locations of
crack initiation in the shear test and the shear stiffness of the joint in-
creases. It means that the laser Surfi-Sculpt® technology can greatly
improve the shear force and shear strength of mild steel/CFRP joint.
4. Conclusions
In the present paper, the effect of laser Surfi-Sculpt® on the forma-
tion of shrinkage porosity in melted zone of CFRP/steel joint is in-
vestigated. And the mechanism of shrinkage porosity suppression re-
sulted from the laser Surfi-Sculpt® is revealed.
Both protrusion height and protrusion density have important influence
on shrinkage porosity formation. With the increase of protrusion height or
protrusion density, the porosity first decreases and then increases. When
protrusion average height is 0.22 mm and protrusion density is 1.25 /mm2,
the porosity reaches the minimum value of 1.26%. The mechanism of
shrinkage porosity suppression is the change of heat conduction and soli-
dification sequence. The heat in the interior of crescent-shaped melted zone
can be conducted across the protrusion to steel quickly, which accelerates
the speed of solidification of the CFRP near the bottom of the melted zone
around the protrusions and inhibits the formation of the hot spot and the
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International Journal of Adhesion and Adhesives 85 (2018) 184–192
capillary. The laser Surfi-Sculpt® technology can effectively suppress the
formation of porosities and greatly improve the shear force and shear
strength of mild steel/CFRP joint.
Acknowledgements
The authors gratefully thank the financial and technical supports from
China Science Lab of GM China, the funding by the National Natural Science
Foundation of China under Grant 51275271, and the funding from
Guangdong Academy of Sciences (No. 2017GDASCX-0113). The authors are
also grateful to Mr. Lei Tang for the assistance on laser Surfi-Sculpt® process
and to Mrs. Yirong Zou for the assistance on porosity calculation.
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