Simulated Effect of Carbon Black on High Speed Laser Transmission Welding of Polypropylene With Low Line Energy

Laser welding is an important manufacturing tool for a wide variety of polymer products including consumer goods, automotive components and medical devices. The laser process parameters and polymer properties have a significant impact on weld quality. Due to higher heat density generated by the laser transmission welding (LTW) technique, defining a set of suitable parameters for LTW of thermoplastics and composites can be challenging. In this work the effect of carbon black along other control parameters has been investigated for high speed welding using a laser source of 980 nm wavelength with low line energy. In this work, the finite element method (FEM)-based software COMSOL Multiphysics is used to create a 3D transient thermal model for LTW of isotactic polypropylene (iPP) and its composites with carbon black (CB) of concentrations ranging from 0.5 wt% to 1.5 wt%. The design of experiments based on Box-Behnken design (BBD) is used to organize the simulation experiments and mathematical models are developed based on multiple curvilinear regression analysis on the simulation findings. Independent control variables include the laser power, welding speed, beam diameter, and carbon black content in the absorbent polymer. The maximum weld temperature, weld width, and weld depth within the transmissive and absorptive layers are considered as dependent response variables. Furthermore, sensitivity analysis is carried out to investigate the impact of carbon black along with other independent variables on the responses. The welding feasibility check was performed on the basis of melt and degradation temperature of the materials, and weld depths of transmissive and absorptive layers. It has been observed that the composites containing 0.5 wt% and 1 wt% of CB can be welded successfully with neat iPP. However, due to a degradation temperature problem, composites having a larger proportion of CB (>1 wt%) appear to be more difficult to weld.

Laser Spot Micro-Welding of Ultra-Thin Steel Sheet

This paper reports a mechanism understanding how to reduce the solder joint failure phenomenon in the laser spot micro-welding process of ultra-thin steel sheets. An optimization method to improve solder joint service life is proposed. In this study, the time-dependent dynamic behaviors of the keyhole and the weld pool are simulated, and the temperatures in the keyhole of two different laser pulse waveforms are compared. The results show that laser energy attenuation mode (LEAM) can only obtain shallow weld depth because of the premature decay of the laser power of waveform, resulting in the laser beam that cannot be concentrated in the keyhole. The temperature inside the keyhole of LEAM fluctuates significantly, which shows a downward trend. Due to the existence of the peak power of waveform in laser energy continuous mode (LECM), the large angle of inclination of the wall of the keyhole inside the melt pool is more conducive to the multiple reflections of the laser beam in the keyhole and increases the absorption rate of the laser energy by the base material, resulting in the “keyhole effect”. But the temperature in the keyhole gradually rises, close to the evaporation temperature. A method combining LEAM and LECM to improve the solder joint service life by optimizing the temperature in the keyhole indirectly by adjusting the peak power of the laser pulse waveform is proposed in this study. The experimental results show that the weld depth can be optimized from 0.135 mm to 0.291 mm, and the tensile strength can be optimized from 88 MPa to 288 MPa. The bonding performance between the upper and lower plates is effectively improved. It can reach the required weld depth in a short time and improve the welding efficiency of the laser spot micro-welding process. The simulation results show that the temperature inside the keyhole is well optimized below the evaporation temperature of the material, which can avoid the violent evaporation of the welding process and keep the whole welding process in a stable state. By optimizing the laser pulse waveform, the temperature inside the keyhole can reach 3300 K, and it is always in a stable state than before optimization. The stable temperature inside the keyhole can help to reduce violent oscillation and spattering of the molten pool and improve welding efficiency and joint life. The research can help provide effective process guidance for the optimization of different laser pulse waveforms in the micro-welding process.

Processing of Keyhole Depth Measurement Data during Laser Beam Micro Welding

Analysing the quality of weld seams is still a challenging task. An optical inspection of the surface is giving limited information about the shape and depth of the weld seam. An application for laser beam welding with high demands regarding the weld depth consistency is the electrical contacting of battery cells. The batteries themselves have a limited terminal or case thickness that must not be penetrated during the welding process to avoid leakage or damage to the cell. That leads to a minimum weld depth to ensure the electrical functionality, and a maximum weld depth indicated by the case thickness. In such applications, a destructive analysis is not suitable which leads to the demand for a non-destructive measurement during the process. Using a coaxial, interferometric measurement setup, the keyhole depth during the deep penetration welding is measureable. For a keyhole with a depth of a couple of millimetres, such a system is commercially available. In micro scale, however, these systems are facing several challenges such as scanning systems, small spot diameters of a few tens of micrometres and narrow keyholes. This study contains an investigation of an interferometric measurement of the keyhole depth and the suitability for laser micro welding. Therefore, the data processing of the achieved measurements is investigated, and the results are compared with the depth measurement of metallographic analysed samples. Stainless steel is used to investigate the behaviour and the stability of developed data processing strategy and the resulting depth values.