Hybrid metal-plastic joining by means of laser (original) (raw)
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Hybrid Joining of Steel and Plastic Materials by Laser Beam
TRANSPORT, 2013
Hybrid joining of metals and plastics in order to produce lightweight parts is of growing interest in the manufacturing processes of vehicles, electrical devices and biomedical applications. In this study, the joining of PMMA plastic (poly methyl metacrylate) and unalloyed steel were investigated by the authors. The authors successfully joined PMMA and steel by means of Nd:YAG laser and carried out tensile tests to measure the joining strength. Experimental results showed that the joint strength is influenced by the heating time, the penetration depth of the steel workpieces in the plastic, by the surface roughness of steel and by the time elapsed between bonding and tearing of the samples.
A Modeling Approach for Plastic-Metal Laser Direct Joining
Lasers in Manufacturing and Materials Processing, 2017
Laser processing has been identified as a feasible approach to direct joining of metal and plastic components without the need for adhesives or mechanical fasteners. The present work sees development of a modeling approach for conduction and transmission laser direct joining of these materials based on multi-layer optical propagation theory and numerical heat flow simulation. The scope of this methodology is to predict process outcomes based on the calculated joint interface and upper surface temperatures. Three representative cases are considered for model verification, including conduction joining of PBT and aluminum alloy, transmission joining of optically transparent PET and stainless steel, and transmission joining of semitransparent PA 66 and stainless steel. Conduction direct laser joining experiments are performed on black PBT and 6082 anticorodal aluminum alloy, achieving shear loads of over 2000 N with specimens of 2 mm thickness and 25 mm width. Comparison with simulation results shows that consistently high strength is achieved where the peak interface temperature is above the plastic degradation temperature. Comparison of transmission joining simulations and published experimental results confirms these findings and highlights the influence of plastic layer optical absorption on process feasibility.
Laser Assisted Joining of Metal Pins and Thin Plastic Sheets
Physics Procedia, 2012
The joining of plastics and metals in order to produce lightweight but robust parts has become more significant in the process of vehicle manufacturing. In the course of this study, the authors joined PMMA plastic and steel in a pin to plate geometry by pulsed Nd:YAG laser. Tensile tests were carried out to investigate the effects of heating time, the laser settings, the surface roughness and the clamping force on the joining strength. Experimental results showed that the joining is feasible and using adequate settings the strength can be optimised.
Investigating Thermal Interactions in the Case of Laser Assisted Joining of PMMA Plastic and Steel
Physics Procedia, 2014
Laser transmission joining of dissimilar materials is a novel and promising area of researches on joining technology. However, processes during laser assisted metal plastic (LAMP) joining are not completely explained yet. In the course of this study, the authors investigated the joining process of PMMA plastic and steel by means of laser, as a part of their research on dissimilar material joining. The characteristic process temperature was measured during the joining by different heating conditions, to describe thermal interactions between the polymer and the metal part, and to better understand the mechanism of joining.
Laser Assisted Joining of Dissimilar Materials
2011
Joining of dissimilar materials is often challenging due to different material properties. Laser welding is an attractive technique compared to conventional joining techniques of dissimilar metals since processing speed and precision are high whereas heat input is very low. Laser assisted joining of dissimilar materials, like aluminum alloys – steel, aluminum alloys – titanium and hard metals – steel has been examined with high power Nd:YAG and diode lasers. Joining of aluminum alloys from 5XXX and 6XXX groups (AlMg3 and AlMgSi1) and titanium or micro alloyed steel H340 (galvanized and non-galvanized) have been investigated. Additionally, butt joints between hard metals K40 (86% tungsten carbide, 12 % cobalt and 2% titanium and tantalum carbide) and carbon steel C75 (tensile strength 1450 N/mm) have been examined. A 1 kW diode laser as well as 3 kW Nd:YAG laser have been used for experiments. Microstructure and mechanical properties of laser welded samples have been investigated by ...
A Review on Laser-Assisted Joining of Aluminium Alloys to Other Metals
Metals
Modern industry requires different advanced metallic alloys with specific properties since conventional steels cannot cover all requirements. Aluminium alloys are becoming more popular, due to their low weight, high corrosion resistance, and relatively high strength. They possess respectable electrical conductivity, and their application extends to the energy sector. There is a high demand in joining aluminium alloys with other metals, such as steels, copper, and titanium. The joining of two or more metals is challenging, due to formation of the intermetallic compound (IMC) layer with excessive brittleness. High differences in the thermophysical properties cause distortions, cracking, improper dilution, and numerous weld imperfections, having an adverse effect on strength. Laser beam as a high concentration energy source is an alternative welding method for highly conductive metals, with significant improvement in productivity, compared to conventional joining processes. It may prov...
Procedia Engineering, 2017
In principle, a laser can weld any materials, which can be joined by conventional and other nonconventional processes. Dissimilar joining technologies find applications in many sectors including microelectronics, medical and aerospace. The laser weldability of dissimilar materials depends on many factors such as physical and chemical properties. In the presented study, the laser lap joint of stainless steel 304 and acrylonitrile butadiene styrene (ABS) is investigated using a continuous wave fiber laser. All the important parameters such as laser power and welding speed based on full factorial method have been considered in this paper. The quality criteria considered to determine the optimal parameter settings were the maximization of shearing force. The collected data has been analyzed by analysis of variance (ANOVA) method to find the significance factor that effects on laser welding of stainless steel 304 and ABS. A focused beam with laser power 230 W and welding speed 16 mm/s were identified as the optimal set of laser welding parameters to obtain stronger and better welds. This research is conducted to reveal the possible of strong dissimilar lap joint by a direct joining laser radiation without using adhesive bonds or mechanical fasteners.
Journal of Manufacturing Processes, 2019
Direct laser joining of metal to plastic materials is one of the cost effective methods of joining. The demand for laser welding of stainless steels and thermoplastics is going on increase because of having many applications such as automotive, aerospace and aviation industries. This paper presents the experimental investigation of direct laser joining of stainless steel 304 and Acrylonitrile Butadiene Styrene (ABS). The effects of pulsed laser parameters including laser welding speed, focal length, frequency and power on the themperature field and tensile shear load was investigated. The results showed that excessive increase of the joint interface temperature mainly induced by high laser power density results in exiting of the more volume of the molten ABS from the stainless steel melt pool. Also, increasing the laser power density through decreasing the focal length or increasing the laser power led to an increase in the surface temperature, higher beam penetration and high volume of molten ABS. Decreasing the focal length from 5 to 2 mm significantly rose the temperature from 150 to 300°C. By increasing the laser pulse frequency, the number of bobbles at the ABS interface surface remarkably increased where the temperature increased from 120 to 180°C. The X-ray spectroscopy results showed the existence of the polymer elements on the metal surface at the joint interface zone. The tensile shear load clearly increased from 280 to 460 N with augmentation of laser average power from 180 W to 215 W. Applying higher levels of laser power has clearly decreased the tensile shear load due to creating bigger bobbles and more cavities at the adhesive zone.
The International Journal of Advanced Manufacturing Technology, 2020
Laser-assisted metal-polymer joining (LAMP) is a novel assembly process for the development of miniaturized joints in hybrid lightweight products. This work adopts a design of experiments (DoE) approach to investigate the influence of several laser welding parameters on the strength and quality of titanium alloy (Ti-6Al-4V)-polyamide (PA6.6) assembly. Significant parameters were highlighted using the Plackett Burmann design, and process window was outlined using the Response Surface Method (RSM). A statistically reliable mathematical model was generated to describe the relation between highlighted welding parameters and joint strength. The analysis of variance (ANOVA) method was implemented to identify significant parametric interactions. Results show the prominence of focal position and laser power, as well as significant interaction between laser power and beam speed, on the joint strength. The evolution of weld defects (bubbles, excessive penetration, flashing, titanium coloring, weld pool cavities, and welding-induced deflection) along the process window was investigated using optical microscopy. The resulted deflection in titanium was quantified, and its relationship with welding parameters was mathematically modeled. Robust process window was outlined to maintain insignificant deflection in the welded joints. Results showed that the growth of weld defects correlates with a decline in joint strength. Optimal parameters demonstrated a defect-free joint, maximizing joint strength.