This paper presents an experimental study to evaluate the feasibility, characteristics and mechanism of laser direct joining between metal and carbon fiber reinforced plastic (PA66CF20). This study presents a method to improve the joint strength of the metal-polymer hybrid joint. The investigation study effects of process parameters (laser power and travelling speed) on the quality of joining joint. Macroscopic morphology of joint and PA66CF20 melting region closed to the interface were observed in this study. XPS analysis shows that Ti-C and Ti-O chemical bonding were produced between titanium alloy and plastic. Cross-sectional photo showed the melted polymer flowed into micro-cavity of metal surface caused by roughness of metal and thus formed mechanical bonding. Finally, the titanium alloy surface was structured in four different surface textures using a pulsed laser. Then the metal was joined with the plastic. The result shows that the joint strength of metal after laser-structured joining with plastic had been improved greatly.
Laser impact welding (LIW) is a novel welding technique which uses laser induced shock waves to obtain the solid-state and metallurgical bonding between flyer and base plates, and can be applied in welding of dissimilar metal plates in micron level. In this paper, experimental study is conducted with titanium as the flyer plate and aluminum as the base plate under different laser energies and laser spot diameters. Besides, the microstructure and mechanical properties of the welding joints are also investigated. The wavy interface is observed by metallographic investigation which is similar to explosive welding and electromagnetic pulse welding. Moreover, the micro-hardness taken from the interface region shows an obvious improvement compared with the base metal. It is also found that laser shock welding results in fine grained structure of titanium on the weld interface. In conclusion, laser shock welding can not only improve the material microstructure of weld interface, but also avoid the heat affected zone and formation of intermetallic phase during dissimilar metal welding. Therefore, it is a promising welding technology in the field of MEMS.
Laser-driven flyer micro forming process is a promising microforming technology with the advantage of high efficiency, low cost, high flexibility. A series of experiments are conducted to investigate forming ability of aluminum foil with the thickness of 50μm. The effect of forming temperature and laser energy on forming ability characterized by forming depth, forming accuracy and surface quality is quantitatively analyzed. It is found that forming depth observed through three dimensional topography increases with the enhancement of forming temperature and laser energy. By elevating the forming temperature, the preheated workpiece suffers more homogenous deformation, presenting better forming accuracy. However, a certain degree of deterioration of surface integrity at the forming temperature of 200°C can be attributed to the earlier appearance of micro cracks caused by excessive thinning even at low laser energy. Overall, it is concluded that the optimal forming temperature is appropriately 150°C as the forming depth and forming accuracy is improved with no deterioration of the surface integrity.
A laser direct joining (LDJ) experiment of titanium alloy (Ti-6Al-4V) and carbon fiber reinforced nylon (PA66CF20) is presented here using diode laser equipment. Experimental design and experiment of LDJ are carried out according to a single process parameters range obtained from the previous experiment. Response surface methodology (RSM) in Design-Expert v7 software is adopted to establish the mathematical model between LDJ process parameters and joint quality. Then the interaction effects of joining process parameters (laser power, scan speed and stand-off distance) on joint quality are investigated using analysis-of-variance (ANOVA), and the result shows that the interaction effect of laser power and scan speed on joint quality is the greatest. Finally, the predicted values from the mathematical model established by RSM are compared with the experimental values, and the process parameters are optimized to obtain the strongest joint strength. The result suggests that the predicted values are in good agreement with the experimental ones. The purpose of predicting and optimizing joint quality based on reasonable process parameters is achieved.
This paper presents a laser transmission joining (LTJ) experiment between thermoplastic Polycarbonate (PC) and glass reinforced nylon (PA66GF) using diode laser equipment. Laser transmission joining experimental design and experiment are carried out according to a single process parameters window. Response surface methodology (RSM) in Design-Expert v7 software is employed to develop mathematical models between LTJ process parameters and joint strength. The interaction effects of joining process parameters (line energy, spot diameter, clamp pressure) on the joint strength are investigated using analysis-of-variance (ANOVA), the result shows that the interaction effect of line energy and spot diameter has maximum influence on the joint quality. Finally, the predicted values from mathematical models developed by RSM are compared with the experimental values and it is found that they are nearly agreed with each other. The purpose of predicting joint strength based on reasonable process parameters is achieved.
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