Analysis of Temperature Distribution in Laser Assisted Metal Polymer (LAMP) Joining
AbstractThe need for lightweight components, reduced cost, and improved efficiency in modern manufacturing has led to increasing interest towards hybrid polymer-metal components with optimized characteristics. This has resulted to development of new components with tailored properties for application in aerospace, energy generation, medical and electronics as well as for consumer goods. Laser Assisted Metal to Polymer (LAMP) joining is a modern technique used in joining metals to polymers by irradiation of a laser beam to the metal-polymer interface to melt the polymer for bonding. During the LAMP process, excessive heat could lead to degradation of the polymer while insufficient heat could lead to uneven melting. These results to improper joints, and therefore, there is a need to regulate the amount of heating in the process. Delivery of the thermal energy by the laser beam is affected by parameters such as laser beam power, scanning speed, the absorptivity of the materials, and the contact pressure at the interface. To attain uniform temperature distribution and optimum temperature values for proper melting of the polymer, a careful selection of these parameters is essential. In this paper, a finite element model is developed to investigate the influence of different laser parameters on temperature distribution at the interface during LAMP joining. This model is used to predict the depth and width of the molten zone, and temperature distribution within the heat-affected zone. Simulation runs are carried out for the joining of Polyethylene Terephthalate (PET) polymer and stainless steel plate (SUS304) materials. Their common application in LAMP joining provides the motivation to use them as case study for this research. From the analysis, it is seen that increasing laser power and decreasing laser scan speed leads to the increase of the interface temperatures and dimensions of the molten zone. A comparison is made for the predicted width of melt with experimental bond width. The results for the range of parameters used are in good agreement and have a maximum deviation of 6%.
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