Surface Analysis of Two-Layer Aluminum-Silicone Structure After High-Pressure Abrasive Water Jet Cutting

This study examines the impact of high-pressure abrasive water jet (AWJ) cutting on the surface topography of a two-layer aluminum 5754-silicone composite, representative of layered materials used in aerospace applications. The cutting process was performed using the Eckert Opal WaterJet COMBO system, and surface morphology was assessed via 3D optical profilometry using Alicona Infinite Focus. Three material zones were analyzed-the aluminum surface, the silicone layer, and their interface-under varying process conditions, specifically feed rate and abrasive mass flow rate (0.4 and $0.8 \mathrm{~g} / \mathrm{s}$). The results indicate that lower abrasive flow leads to a $12-15 \%$ increase in surface roughness, and distinct roughness trends were observed across material layers. The findings contribute to better understanding and optimization of AWJ machining in hybrid, aerospace-relevant structures.