Igneous Rock Metal Composites: Robotic prototyping and testing of segmented stone metal beam

Volcanic rock masonry is a promising building material due to its natural abundance in volcanic regions. its renewable nature, and its inherent material characteristics. Our research aims at producing a method to fabricate and assemble segmented beams, to bridge horizontal spans and overcome historical limitations of stone construction. We explore the advantages, and challenges, of a rockmetal composite using pyroclastic igneous rock infiltrated with cast aluminium. The methodology consists of manufacturing rock blocks using a 230 mm diameter diamond coated blade mounted on a KUKA KR180 R2500 heavy-duty robotic arm. We focus on the characterization of the rock, with optical microscopy before and after infiltration. Compression tests for the rock were performed according to ASTM 5731 and the aluminium was infiltrated at two different temperatures, 850°C and 950°C. Morphological characterization, showed vesicle sizes between 40 μm and 1994 μm. Meanwhile, the compression tests indicated adequate strength for local construction regulation. After infiltrating and sectioning the composite beam, a complex interface between the aluminum and the rock is observed, exposing the vesicular penetration of the aluminum, depending on local porosity.