Laser Transmission Welding of Thermoplastics—Part II: Experimental Model Validation

2007 ◽  
Vol 129 (5) ◽  
pp. 859-867 ◽  
Author(s):  
James D. Van de Ven ◽  
Arthur G. Erdman
Keyword(s):  
Polyvinyl Chloride ◽  
Welding Process ◽  
Weld Strength ◽  
Average Error ◽  
Welding Parameters ◽  
Laser Transmission Welding ◽  
Weld Width ◽  
Additional Information ◽  
Primary Model ◽  
Clamping Pressure

Two laser transmission welding experiments involving polyvinyl chloride are presented that aim to validate a previously presented welding model while helping to further understand the relationship between welding parameters and weld quality. While numerous previous research papers have presented the results of laser welding experiments, there exists minimal work validating models of the welding process. The first experiment explores the interaction of laser power and welding velocity while the second experiment explores the influence of clamping pressure. Using the weld width as the primary model output, the agreement between the welding experiments and the model have an average error of 5.6%. This finding strongly supports the validity of the model presented in Part I of this two paper set (Van de Ven and Erdman, 2007, ASME J. Manuf. Sci. Eng., 129, pp. 849–858). Additional information was gained regarding the operating window for laser transmission welding and the thermal decomposition of polyvinyl chloride. Clamping pressure was found to provide a small, but not statistically significant, influence on the visual appearance, weld width, and weld strength.

Experimental Investigation on Laser Transmission Welding of Polycarbonate and Acrylic

2021 ◽  
pp. 160-180
Author(s):  
Dhiraj Kumar ◽  
Sudipta Paitandi ◽  
Arunanshu Shekhar Kuar ◽  
Dipankar Bose
Keyword(s):  
Mathematical Model ◽  
Process Parameters ◽  
Welding Speed ◽  
Laser Power ◽  
Optimum Parameter ◽  
Optimization Technique ◽  
Welding Process ◽  
Parameter Setting ◽  
Laser Transmission Welding ◽  
Weld Width

This chapter presents the effect of various process parameters, namely laser power, pulse frequency, and welding speed, on the weld shear strength and weld width using a diode laser system. Here, laser transmission welding of transparent polycarbonate and black carbon filled acrylic each of 2.8 mm thickness have been performed to create lap joint by using low power laser. Response surface methodology is applied to develop the mathematical model between the laser welding process parameters and the responses of weld joint. The developed mathematical model is tested for its adequacy using analysis of variance and other adequacy measures. It has been observed that laser power and welding speed are the dominant factor followed by frequency. A confirmation test has also been conducted to validate the experimental results at optimum parameter setting. Results show that weld strength of 34.3173 N/mm and weld width of 2.61547 mm have been achieved at optimum parameter setting using desirability function-based optimization technique.

scholarly journals A Novel Method of Defect Detection Based on Experimental Investigation of Galvanized Steel Welded Plates Using Wobble Laser Process

2021 ◽  
Author(s):  
Sasan Sattarpanah Karganroudi ◽  
Ahmad Aminzadeh ◽  
Vincent Blériot Feujofack Kemda ◽  
Noureddine Barka
Keyword(s):  
Process Parameters ◽  
Predictive Models ◽  
Welding Process ◽  
Galvanized Steel ◽  
Welding Parameters ◽  
Indentation Hardness ◽  
Hardness Profile ◽  
Weld Width ◽  
Welding Defects ◽  
Geometrical Defects

Abstract This paper aims at investigating the effect of laser welding parameters on the hardness profile, using hardness mapping analyses, and welding geometry of galvanized steel plates. Hardness distribution and geometry deflection of galvanized welded thin plates are commonly applied in fields where the weld quality is of utmost importance. Due to the welding process and material condition, welding galvanized steel is one of the problematic matters in welding technology. Here, the design of experiment (DOE) approach is used to study the effect of process parameters. Using a pattern matrix of micro-indentation hardness experiment, the welding defects are visualized on hardness profile of the weld cross-section. The effect of process parameters on welding defect formation is then qualitatively analyzed. The geometrical defects of welding such as weld width and voids are then quantitatively studied based on analysis of variance (ANOVA), and predictive models of welding voids and weld seam width are developed based on the regression method. Response surface method (RSM) is then applied to define the trend of process factors interaction on the welding defects. The experimental results confirm the reliability of developed predictive models of welding defects geometry, weld width, and voids area of laser-welded galvanized plates.

An Investigation about Welding Parameters of Polypropylene Matrix Composite

2015 ◽  
Vol 729 ◽  
pp. 67-72
Author(s):  
Umit Huner ◽  
E. Selcuk Erdogan
Keyword(s):  
Matrix Composite ◽  
Welding Process ◽  
Break Point ◽  
Heating Time ◽  
Inorganic Materials ◽  
Weld Strength ◽  
Welding Parameters ◽  
Butt Welding ◽  
Base Strength ◽  
Polypropylene Matrix

This paper presents an experimental investigation of heated tool welding of polypropylene matrix composite. The goals of this paper are to investigate the issues of local changes of welding strength that depends on heating time. For experimental procedure, specimens were injection molded as ISO tensile test specimens and matrix was reinforced by organic and inorganic materials. In addition, welding of specimens was carried out by non-contact heated tool butt welding process. Within the range of the weld process parameters were investigated, the highest weld strength dependent on heating time was achieved of the order of 94% to the base strength of the material. And then these specimen’s maximum welding strengths and energy at break point properties that were depend on heating time have been compared.

scholarly journals Research Status and Prospect of Laser Impact Welding

Metals ◽  
2020 ◽  
Vol 10 (11) ◽  
pp. 1444 ◽  
Author(s):  
Kangnian Wang ◽  
Huimin Wang ◽  
Hongyu Zhou ◽  
Wenyue Zheng ◽  
Aijun Xu
Keyword(s):  
Solid State ◽  
Welding Process ◽  
Research Progress ◽  
Weld Strength ◽  
Welding Parameters ◽  
Base Materials ◽  
Atomic Force ◽  
Impact Welding ◽  
Laser Impact ◽  
Laser Impact Welding

The demands for the connection between thin dissimilar and similar materials in the fields of microelectronics and medical devices has promoted the development of laser impact welding. It is a new solid-state metallurgical bonding technology developed in recent years. This paper reviews the research progress of the laser impact welding in many aspects, including welding principle, welding process, weld interface microstructure and performance. The theoretical welding principle is the atomic force between materials. However, the metallurgical combination of two materials in the solid state by atomic force but almost no diffusion has not been confirmed by microstructure observation. The main theories used to explain the wave formation in impact welding were compared to conclude that caved mechanism and the Helmholz instability mechanism were accepted by researchers. The rebound of the flyer is still a critical problem for its application. With proper control of the welding parameters, the weld failure occurs on the base materials, indicating that the weld strength is higher than that of the base materials. Laser impact welding has been successfully applied in joining many dissimilar materials. There are issues still remained unresolved, such as surface damage of the flyer. The problems faced by laser impact welding were summaried, and its future applications were proposed. This review will provide a reference for the studies in laser impact welding, aiming process optimization and industrial application.

Microstructure and Mechanical Performance of Cold Metal Transfer Spot Joints of AA6061-T6 to Galvanized DP590 Using Edge Plug Welding Mode

2016 ◽  
Vol 138 (7) ◽  
Author(s):  
Haiyang Lei ◽  
Yongbing Li ◽  
Blair E. Carlson ◽  
Zhongqin Lin
Keyword(s):  
Mechanical Performance ◽  
Welding Process ◽  
Metal Transfer ◽  
Weld Nugget ◽  
Weld Strength ◽  
Welding Parameters ◽  
Feed Speed ◽  
Cold Metal Transfer ◽  
Lap Shear ◽  
Cold Metal

Dissimilar joining of aluminum to steel poses a challenge for arc welding. In this study, aluminum AA6061-T6 and hot dipped galvanized DP590 steel were joined using the Fronius cold metal transfer (CMT) welding process applying an edge plug welding mode (EPW). The correlation of the welding parameters, weld characteristics, and weld strength was systematically investigated. It was found that the EPW mode created a zinc-rich zone at the weld root along the Al–steel faying interface which transitioned to a continuous and compact intermetallic compounds (IMC) layer in the middle portion of the joint. The fracture propagation in lap-shear specimens was affected by this increase of IMC layer thickness. At a wire feed speed (wfs) of 5.6 m/min, the fracture initiated along the zinc-rich layer at the faying interface and then, upon meeting the compact IMC layer, propagated into the aluminum weld nugget. Propagation followed a path within the weld nugget along the boundary between columnar and equiaxed grains leading to weld nugget pullout upon fracture. For IMC layer peak thicknesses below 10 μm, the strength increased as a function of weld nugget diameter. However, larger heat inputs resulted in IMC layer thicknesses greater than 10 μm and interfacial fracture.

Micro Thin Film Sensor Embedded in Metal Structures for In-Situ Process Monitoring During Ultrasonic Welding

2005 ◽  
Author(s):  
Xudong Cheng ◽  
Xiaochun Li
Keyword(s):  
Thin Film ◽  
Heat Generation ◽  
Welding Process ◽  
Ultrasonic Welding ◽  
Weld Strength ◽  
Welding Parameter ◽  
Welding Parameters ◽  
Thin Film Sensors ◽  
Welding Interface

The objective of this research is to develop an effective method, i.e., ultrasonic metal welding (USMW), to embed micro thin film sensors for metal tooling, and use micro thin film thermocouple study the heat generation during USMW. A complete understanding of the fundamental mechanisms of USMW does not yet exist, and the function of heat generation on weld formation is especially in argument due to the lack of the method to measure the temperature at the welding interface. Continuing on the previous preliminary study [1] which proved that thin film sensors can survive ultrasonic welding process, significant advances were made to improve sensor reliability as well as sensor fabrication effectiveness. These include the development of a new approach for batch production of the sensor units, improvement of the adhesion between metal encapsulating layers for the sensor, as well as the adhesion between the sensing layer and the dielectric layer. Welding experiments are conducted using a series of welding parameter settings with the in-situ data acquisition of temperature 50 μm away from the welding interface. Attempts are then made to correlate the heat generation to welding parameters. With the mechanical testing of the weld strength, the possibility of using heat generation as a weld strength indicator is explored.

Optimization of Laser Transmission Welding Parameters Using Chicken Swarm Optimization Algorithm

2017 ◽  
pp. 142-161
Author(s):  
Bappa Acherjee ◽  
Debanjan Maity ◽  
Arunanshu S. Kuar ◽  
Souren Mitra ◽  
Dipten Misra
Keyword(s):  
Process Parameters ◽  
Research Work ◽  
Parametric Modeling ◽  
Weld Strength ◽  
Welding Parameters ◽  
Swarm Optimization ◽  
Laser Transmission Welding ◽  
Cycle Times ◽  
Increasing Demand ◽  
Chicken Swarm Optimization

The ever-increasing demand of high quality joints with improved cycle times leads the industries, those involve welding of plastics, to use laser for welding plastics. Laser transmission welding is the latest development in the field of welding of plastics. In present research work, experimental investigation, parametric modeling and optimization of laser transmission welding of polycarbonate is carried out. A systematic experimental plan is executed using central composite design of response surface methodology (RSM). Mathematical models are developed using RSM for establishing an interrelationship between the process parameters and the responses of interest. Chicken swarm optimization (CSO) algorithm is employed with the developed RSM models to set the optimal process parameters combinations to achieved desired weld qualities. Here, the objectives are set as to increase the weld strength and decrease the weld width independently, as well as simultaneously. The interdependent parametric trends are also studied and discussed.

Laser Transmission Welding of Thermoplastic: Effect of Process Parameters on Weld Strength

2014 ◽  
Vol 852 ◽  
pp. 463-466
Author(s):  
Se Kou Singare ◽  
Shen Gui Chen ◽  
Jian Jun Zou ◽  
Yong Zhou Lin
Keyword(s):  
Shear Strength ◽  
Cross Sections ◽  
Laser Power ◽  
Testing Machine ◽  
Polarized Light ◽  
Weld Strength ◽  
Welding Parameters ◽  
Laser Transmission Welding ◽  
Universal Testing ◽  
Weld Area

This paper investigates the effect of the laser welding parameters such as laser power, welding speed on weld strength. A 30W fiber laser with wavelength 1064nm has been used to weld transparent and absorbing acrylics in lap weld configuration. The force at break of the lap welds was assessed on the Universal testing machine,the shear strength was calculated by dividing the force at break by the weld area. Weld fracture surfaces and weld cross-sections were also analyzed under microscope using reflected polarized light to qualitatively assess the weld quality.

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