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Simulation-based investigation on the temperature influence in laser transmission welding of thermoplastics

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Abstract

Because of several advantages, e.g., an exact and high energy input, laser transmission welding has become more and more important in the last few years. Due to the contactless energy input, a sufficient process control is a challenge. In industrial production, the process parameters for a good weld seam are qualified by the energy input, which describes the process parameters laser power, laser velocity and irradiation time. These process parameters lead to the welding temperature, which influence the weld seam quality. The question remaining is whether the energy input describes the weld strength sufficiently or whether the welding temperature has a higher influence on the weld quality. In this study, the influence of the energy input on the weld quality is determined for an industrially relevant material combination (PBT ASA-GF20 and PC) in experimental examinations for quasi-simultaneous laser transmission welding. The welding temperature for every design point is calculated and the influence of the temperature on the weld strength is analyzed in an FEM model. In order to compare the influences of the two factors, welding temperature and energy input, a correlation analysis is performed. The correlation analysis shows a higher influence of the welding temperature on the weld strength compared to the energy input. But the energy input is also able to describe the weld strength.

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Abbreviations

ASA:

acrylonitrile-styrene-acrylonitrile

c :

z-transformation

E s :

energy input

FEM:

Finite element method

F ( r) :

Fisher-transformation

GF:

glass fiber (reinforced)

I 0 :

maximum intensity of the Gaussian laser beam

\( {\overline{I}}_n \) :

intensity of simultaneous welding at the surface for the thermal source (\( {\dot{\phi}}_{n,1} \)) in the FEM model

\( {\overline{I}}_n(z):: \) :

averaged intensity in the z-direction for the thermal source (\( {\dot{\phi}}_{n,1} \)) in the FEM model

\( {\overline{I}}_{(x)} \) :

intensity of simultaneous irradiation

K :

absorption coefficient

LTW:

laser transmission welding

m :

number of design points

N :

number of scans

n :

numbers of thermal sources

PBT:

polybutylene terephthalate

PC:

polycarbonate

P L :

laser power

p J :

joining pressure

QSW:

quasi-simultaneous welding

r σ, T :

correlation coefficient of the weld strength and welding temperature

s :

range of the confidence interval (z-transformation)

s J :

joining displacement

t :

t value

t :

process time

t u :

time of one scan

\( {\overline{T}}_R \) :

averaged ranked welding temperature

T R, i :

ranked welding temperature of the design point i

v s :

scanning speed

w :

laser beam diameter

x :

x-coordinate

∆x :

width of the thermal source (\( {\dot{\phi}}_{n,1} \)) in the FEM model

z :

z-coordinate

∆z :

height of the thermal source (\( {\dot{\phi}}_{n,1} \)) in the FEM model

α :

significance level

ε all :

all strain

ε ij el :

elastic strain

ε ij pl :

plastic strain

ε ij th :

thermal strain

\( {\dot{\phi}}_{n,1} \) :

thermal source in the FEM model

\( {\overline{\sigma}}_R \) :

averaged ranked weld strength

σ R, i :

ranked weld strength of the design point i

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Authors and Affiliations

  1. Kunststofftechnik Paderborn, Paderborn University, Paderborn, Germany

    Patrick Lakemeyer & Volker Schöppner

Authors
  1. Patrick Lakemeyer
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  2. Volker Schöppner
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Corresponding author

Correspondence to Volker Schöppner.

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Recommended for publication by Commission XVI - Polymer Joining and Adhesive Technology

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Lakemeyer, P., Schöppner, V. Simulation-based investigation on the temperature influence in laser transmission welding of thermoplastics. Weld World 63, 221–228 (2019). https://doi.org/10.1007/s40194-018-00696-8

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  • DOI: https://doi.org/10.1007/s40194-018-00696-8

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