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Laser Beam Joining of the Material Pairings Aluminum/Polyamide and Aluminum/Polyvinylchloride

Received: 1 May 2022     Accepted: 25 May 2022     Published: 30 June 2022
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Abstract

The article presents a process optimization of laser beam joining of the material pairings EN AW-6082 (AlSi1MgMn)/polyamide 6.6 and EN AW-6082/polyvinylchloride hard. The materials selection focuses on their distinct mechanical and electrical properties. Al and PA-6.6 are both widely used but dissimilar light-weighting materials for engineering applications, while Al and PVC represent the combination of a weldable electrical conductor with typical insulation material. The contrariety of these materials potentially acts complementary as highly integrated hybrid structures. However, this dissimilarity also poses distinct challenges to joining polymers with metals. Usually, the material pairing aluminum/plastic has been bonded for industrial applications in the recent past. The investigations provide information on the influence of various parameters on the joint and the individual joining partners themselves and which combination offers the best joining results. In addition, it is shown that specific pre-treatment methods of the test materials, especially for aluminum, can significantly increase the joining quality and offer further optimization potential. Furthermore, the complexity of such an optimization process becomes apparent because it is not only limited to the parameter variation of the laser. The periphery design, such as the sample clamping and the pre-treatment of the joining partners, are similarly essential adjustment parameters. The laser-joined specimens are compared in a tensile test against conventionally bonded specimens for their mechanical-technological properties. It can be shown that the shear strength of joined specimen is significantly higher in comparison to the bonded specimen. Thereby an alternative to conventional bonding processes can be offered. Moreover, the extremely short process time of laser beam joining combined with instant handling is particularly attractive for industrial applications. The laser joining process described in this article aims to contribute to the future development of laser-based multi-material additive manufacturing technologies. In this way, the envisioned direct joining principle could enable the production of highly integrated parts of unseen complexity.

Published in Engineering Physics (Volume 6, Issue 1)
DOI 10.11648/j.ep.20220601.13
Page(s) 13-19
Creative Commons

This is an Open Access article, distributed under the terms of the Creative Commons Attribution 4.0 International License (http://creativecommons.org/licenses/by/4.0/), which permits unrestricted use, distribution and reproduction in any medium or format, provided the original work is properly cited.

Copyright

Copyright © The Author(s), 2022. Published by Science Publishing Group

Keywords

Laser Beam Joining, Aluminum/Plastics, Comparison to Conventionally Bonded Samples

References
[1] Temesi, T., Czigány, T. (2020). Integrated Structures from Dissimilar Materials: The Future Belongs to Aluminum-Polymer Joints. Advanced Engineering Materials, 22.
[2] Mehrpouya, M., et al (2022) Rapid Prototyping Journal, Multimaterial powder bed fusion techniques, 28 (11), 1–19.
[3] Amor-Dei-Jabo-Cyusa, J., (2022). Master Thesis, Université de Liège, Optimization and Characterization of Metallic Multi-Materials by Laser Powder Bed Fusion.
[4] Cavezza, F., et al (2019), J. Phys. Chem. C, Probing the Metal Oxide/Polymer Molecular Hybrid Interfaces with Nanoscale Resolution Using AFM-IR, 123, 43, 26178–26184.
[5] Chueh, Y-H., et al (2020). Additive Manufacturing, Additive manufacturing of hybrid metal/polymer objects via multiple-material laser powder bed fusion, 36 (1); 101465.
[6] Lamberti, C., (2018). PhD thesis, University of Luxembourg, Optimierung und Charakterisierung einer mittels Laserstrahl gefügten Verbindung zwischen Aluminium und Polyamid 6.6, 128-129.
[7] Jain, J. K. and Sonia, P. (2022). Recent Trends in Welding Polymers and Polymer–Metal Hybrid Structures. In Light Weight Materials (eds K. Kumar, B. S. Babu and J. P. Davim).
[8] R. Falck, S. M. Goushegir, J. F. dos Santos, S. T. Amancio-Filho, (2018). Materials Letters, AddJoining: A novel additive manufacturing approach for layered metal-polymer hybrid structures, 211-214, 217.
[9] Enz, J., (2012). HZG REPORT 2012-2, Laserstrahlschweißen von hochfesten Aluminium-Lithium Legierungen, 11-13; 68.
[10] Tang, Zuhao, (2014). Strahltechnik, Heißrissvermeidung beim Schweißen von Aluminiumlegierungen mit einem Scheibenlaser, Bd. 53, 3-8, BIAS Verlag.
[11] Amanat, N., Chaminade, C., Grace, J., McKenzie, D. R, James, N. L., (2010). Materials and Design, 31 (10), Transmission laser welding of amorphous and semi-crystalline poly-ether-ketone for applications in the medical device industry, 4823-4830.
[12] Kagan, V. A., Kocheny, S. A., Macur, J. E., (2005). Journal of reinforced plastics and composites, Moisture effects on mechanical performance of laser-welded polyamide.
[13] Schricker, K., et al (2015). Wdg. in the World 59, Experimental investigation and modeling of the melting layer in polymer-metal hybrid structures, 407-412.
[14] Miyashita, Y, (2015). Mechanical Engineering J. 2, Formation behavior of bubbles and its effect on joining strength in dissimilar materials laser spot joining between PET and SUS304, 6.
[15] Jung, K., Kawahito, Y., Takahashi, M., Katayama, S. (2013). Materials and Design, 47, Laser direct joining of carbon fiber reinforced plastic to zinc-coated steel, 179-188.
[16] Jung, K., Kawahito, Y., Katayama, S., (2014). International Journal of Precision Engineering and Manufacturing-Green Technology, Mechanical property and joining characteristics of laser direct joining of CFRP to polyethylene terephthalate, 43-48.
[17] Katayama, S., Kawahito, Y., (2008). Scripa Materialia, 59, Laser direct joining of metal and plastic, 1247-1250.
[18] Yusof, F., Miyashita, X., Seo, N., Mutoh, Y., Moshwan, R. (2012). Science and Technology of Welding and Joining 17, Utilising friction spot joining for dissimilar joint between aluminum alloy (A5052) and polyethylene terephthalate, 544-549.
[19] Lamberti, C, Peral Alonso, I., (2017). Atiner Conference Paper Series No. IND2017-2270, Athens, Influence of Material Moisture during Laser Joining of Polyamide 6.6 to Aluminum.
[20] Farazila, Y., Miyashito, Y., Hua, W., Mutoh, Y., Otsuka, Y., (2011). JLMN-Journal of Laser Micro/Nanoengineering 6 (1), YAG laser spot welding of PET and metallic materials, 69-74.
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  • APA Style

    Christian Lamberti, Peter Böhm. (2022). Laser Beam Joining of the Material Pairings Aluminum/Polyamide and Aluminum/Polyvinylchloride. Engineering Physics, 6(1), 13-19. https://doi.org/10.11648/j.ep.20220601.13

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    ACS Style

    Christian Lamberti; Peter Böhm. Laser Beam Joining of the Material Pairings Aluminum/Polyamide and Aluminum/Polyvinylchloride. Eng. Phys. 2022, 6(1), 13-19. doi: 10.11648/j.ep.20220601.13

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    AMA Style

    Christian Lamberti, Peter Böhm. Laser Beam Joining of the Material Pairings Aluminum/Polyamide and Aluminum/Polyvinylchloride. Eng Phys. 2022;6(1):13-19. doi: 10.11648/j.ep.20220601.13

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  • @article{10.11648/j.ep.20220601.13,
      author = {Christian Lamberti and Peter Böhm},
      title = {Laser Beam Joining of the Material Pairings Aluminum/Polyamide and Aluminum/Polyvinylchloride},
      journal = {Engineering Physics},
      volume = {6},
      number = {1},
      pages = {13-19},
      doi = {10.11648/j.ep.20220601.13},
      url = {https://doi.org/10.11648/j.ep.20220601.13},
      eprint = {https://article.sciencepublishinggroup.com/pdf/10.11648.j.ep.20220601.13},
      abstract = {The article presents a process optimization of laser beam joining of the material pairings EN AW-6082 (AlSi1MgMn)/polyamide 6.6 and EN AW-6082/polyvinylchloride hard. The materials selection focuses on their distinct mechanical and electrical properties. Al and PA-6.6 are both widely used but dissimilar light-weighting materials for engineering applications, while Al and PVC represent the combination of a weldable electrical conductor with typical insulation material. The contrariety of these materials potentially acts complementary as highly integrated hybrid structures. However, this dissimilarity also poses distinct challenges to joining polymers with metals. Usually, the material pairing aluminum/plastic has been bonded for industrial applications in the recent past. The investigations provide information on the influence of various parameters on the joint and the individual joining partners themselves and which combination offers the best joining results. In addition, it is shown that specific pre-treatment methods of the test materials, especially for aluminum, can significantly increase the joining quality and offer further optimization potential. Furthermore, the complexity of such an optimization process becomes apparent because it is not only limited to the parameter variation of the laser. The periphery design, such as the sample clamping and the pre-treatment of the joining partners, are similarly essential adjustment parameters. The laser-joined specimens are compared in a tensile test against conventionally bonded specimens for their mechanical-technological properties. It can be shown that the shear strength of joined specimen is significantly higher in comparison to the bonded specimen. Thereby an alternative to conventional bonding processes can be offered. Moreover, the extremely short process time of laser beam joining combined with instant handling is particularly attractive for industrial applications. The laser joining process described in this article aims to contribute to the future development of laser-based multi-material additive manufacturing technologies. In this way, the envisioned direct joining principle could enable the production of highly integrated parts of unseen complexity.},
     year = {2022}
    }
    

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  • TY  - JOUR
    T1  - Laser Beam Joining of the Material Pairings Aluminum/Polyamide and Aluminum/Polyvinylchloride
    AU  - Christian Lamberti
    AU  - Peter Böhm
    Y1  - 2022/06/30
    PY  - 2022
    N1  - https://doi.org/10.11648/j.ep.20220601.13
    DO  - 10.11648/j.ep.20220601.13
    T2  - Engineering Physics
    JF  - Engineering Physics
    JO  - Engineering Physics
    SP  - 13
    EP  - 19
    PB  - Science Publishing Group
    SN  - 2640-1029
    UR  - https://doi.org/10.11648/j.ep.20220601.13
    AB  - The article presents a process optimization of laser beam joining of the material pairings EN AW-6082 (AlSi1MgMn)/polyamide 6.6 and EN AW-6082/polyvinylchloride hard. The materials selection focuses on their distinct mechanical and electrical properties. Al and PA-6.6 are both widely used but dissimilar light-weighting materials for engineering applications, while Al and PVC represent the combination of a weldable electrical conductor with typical insulation material. The contrariety of these materials potentially acts complementary as highly integrated hybrid structures. However, this dissimilarity also poses distinct challenges to joining polymers with metals. Usually, the material pairing aluminum/plastic has been bonded for industrial applications in the recent past. The investigations provide information on the influence of various parameters on the joint and the individual joining partners themselves and which combination offers the best joining results. In addition, it is shown that specific pre-treatment methods of the test materials, especially for aluminum, can significantly increase the joining quality and offer further optimization potential. Furthermore, the complexity of such an optimization process becomes apparent because it is not only limited to the parameter variation of the laser. The periphery design, such as the sample clamping and the pre-treatment of the joining partners, are similarly essential adjustment parameters. The laser-joined specimens are compared in a tensile test against conventionally bonded specimens for their mechanical-technological properties. It can be shown that the shear strength of joined specimen is significantly higher in comparison to the bonded specimen. Thereby an alternative to conventional bonding processes can be offered. Moreover, the extremely short process time of laser beam joining combined with instant handling is particularly attractive for industrial applications. The laser joining process described in this article aims to contribute to the future development of laser-based multi-material additive manufacturing technologies. In this way, the envisioned direct joining principle could enable the production of highly integrated parts of unseen complexity.
    VL  - 6
    IS  - 1
    ER  - 

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