Laser transmission welding of polymers – A review on process fundamentals, material attributes, weldability, and welding techniques

Acherjee, Bappa

doi:10.1016/j.jmapro.2020.10.017

Cited by 66 publications

(23 citation statements)

References 138 publications

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“…Laser welding of plastics belong to the class of advanced technologies for joining films, sheets, semi-rigid and rigid components made of polymeric materials by localized heating with a focused beam of laser radiation [1]. Laser transmission welding of plastics can be performed by focusing the laser beam on the joint in two different ways: (i) the laser beam is irradiated to be tangent to the joint interface between the two materials that compose the assembly, of which, at least, one is able to capture the radiation [2]; (ii) the laser beam is irradiated normal to the joint interface across a laser-transparent material, provided that the other material of the assembly or the material posed at the interface is able to absorb the radiation. Laser transmission welding involves, therefore, light absorption, heat generation, heat conduction, melting, mixing, and re-solidification [3].…”

Section: Introductionmentioning

confidence: 99%

“…Laser transmission welding involves, therefore, light absorption, heat generation, heat conduction, melting, mixing, and re-solidification [3]. Different joint configurations were investigated in the literature [2]. However, when a laser transparent polymer is put on top of a laser absorbing material, the most common joint configuration is the lap joint [4].…”

Section: Introductionmentioning

confidence: 99%

“…In fact, T-and butt joint configurations are often affected by the meltdown of the molten or partially molten polymeric material, especially under the pressure normally exerted on the joint interface [6][7][8]. The compositions of polymers can obviously affect the transmission of the laser radiation through the assembly, strongly influencing the final results together with the wavelength of the laser source [2]. Part thickness in the assembly can also play a crucial role, especially when a crystalline or semi-crystalline polymer is investigated.…”

Section: Introductionmentioning

confidence: 99%

“…Basically, the resulting joints feature a strength that remains comparable to the base material strength. A variety of tested polymer combinations and the related laser weldability chart is, however, summarized in Acherjee [2]. Many of the combinations investigated in Acherjee [2] could not be joined by using other conventional methods of polymer welding.…”

Section: Introductionmentioning

confidence: 99%

See 3 more Smart Citations

Laser transmission welding of aluminum film coated with heat sealable co-polyester resin with polypropylene films for applications in food and drug packaging

Gisario

Aversa

Barletta

et al. 2022

Int J Adv Manuf Technol

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The present work deals with the high-power diode laser joining process of aluminum films coated with a polyester resin with polypropylene (PP) films. The first part of the work focused on analyzing the coating process of aluminum films with a polyester resin, using an automatic applicator. The second part of the work was focused on the analysis of the laser joining process of coated aluminum films with plastic counterparts made of PP. Different thicknesses and colors of the PP parts were tested in order to analyze the joining process under a wide range of different conditions. The experimental plan involved the study of the influence of the laser joining parameters, in particular the scanning speed and beam power, on the joints. The joints between aluminum and PP films were subsequently tested by means of tensile and peel-off tests. All the joints between aluminum and PP are obtained through the so-called laser transmission welding (LTW) mechanism. Analysis of the mechanical response of the welded joints allowed to identify the optimal processing window, that is, the choice of the operational parameters that leads to satisfactory welded joints, stating the high potential of laser systems in the joining process of aluminum and PP films for food packaging applications.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Laser transmission welding of aluminum film coated with heat sealable co-polyester resin with polypropylene films for applications in food and drug packaging

Gisario

Aversa

Barletta

et al. 2022

Int J Adv Manuf Technol

View full text Add to dashboard Cite

show abstract

“…Generally laser sources such as Nd: YAG, diode and fibre lasers, can be selected based on operating wavelength suitable for LTW of polymers and their composites. The range of wavelengths include for Nd: YAG as 1064 nm, for diode lasers as 405–1940 nm, for fiber lasers as 1000–2100 nm and CO 2 laser as 10.6 µm [ 31 ]. This review will focus on Laser Transmission Welding (LTW) of polymers based on laser diode CW (commercial welding application) and lap joint welding using CB as filler.…”

Section: Introductionmentioning

confidence: 99%

Laser Transmission Welding of Semi-Crystalline Polymers and Their Composites: A Critical Review

et al. 2021

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The present review provides an overview of the current status and future perspectives of one of the smart manufacturing techniques of Industry 4.0, laser transmission welding (LTW) of semi-crystalline (SC) polymers and their composites. It is one of the most versatile techniques used to join polymeric components with varying thickness and configuration using a laser source. This article focuses on various parameters and phenomena such as inter-diffusion and microstructural changes that occur due to the laser interaction with SC polymers (specifically polypropylene). The effect of carbon black (size, shape, structure, thermal conductivity, dispersion, distribution, etc.) in the laser absorptive part and nucleating agent in the laser transmissive part and its processing conditions impacting the weld strength is discussed in detail. Among the laser parameters, laser power, scanning speed and clamping pressure are considered to be the most critical. This review also highlights innovative ideas such as incorporating metal as an absorber in the laser absorptive part, hybrid carbon black, dual clamping device, and an increasing number of scans and patterns. Finally, there is presented an overview of the essential characterisation techniques that help to determine the weld quality. This review demonstrates that LTW has excellent potential in polymer joining applications and the challenges including the cost-effectiveness, innovative ideas to provide state-of-the-art design and fabrication of complex products in a wide range of applications. This work will be of keen interest to other researchers and practitioners who are involved in the welding of polymers.

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Laser‐Induced Polymerization of Photosensitive Resin for Silk Fabric Joining

Zhou

et al. 2023

Adv Eng Mater

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Herein, a new joining method for silk fabrics based on polymerization of polyurethane acrylate (PUA) photosensitive resin induced by a nanosecond 355 nm ultraviolet laser is proposed. After the resin is applied and cured, not only the space between the fiber bundles, but also the gaps within the bundles are filled up with the resin, forming strong interlocking bonds. The infrared spectra of the joint area indicate that there is no textile burning or chemical change on silk fibers. The increase of laser energy density can improve the polymerization degree of the resin and increase the joint strength. However, when the energy density exceeds 1.68 J cm−2, ablation of the photosensitive resin occurs. The amount of filled resin affects the thickness of the joint and its strength. When the resin filling rate is 0.76 mL min−1, the joint has a high filling density and high bearing capacity. The tensile force of the joint reaches 297.10 N, which is higher than the breaking force of the base silk fabric. The tensile force of the joint also increases with the increasing of the joint width. This study provides an alternative process for conventional sawing and stitching in garments fabrication.

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Laser transmission welding of polymers – A review on process fundamentals, material attributes, weldability, and welding techniques

Cited by 66 publications

References 138 publications

Laser transmission welding of aluminum film coated with heat sealable co-polyester resin with polypropylene films for applications in food and drug packaging

Laser transmission welding of aluminum film coated with heat sealable co-polyester resin with polypropylene films for applications in food and drug packaging

Laser Transmission Welding of Semi-Crystalline Polymers and Their Composites: A Critical Review

Laser‐Induced Polymerization of Photosensitive Resin for Silk Fabric Joining

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