Optimization of laser-assisted joining through an integrated experimental-simulation approach

An integrated experimental-simulation study is carried out to optimize of laser-assisted joining of metals and plastics. An empirical model that predicts the local strength based on the temperature distribution was developed. Experimental mechanical tests were involved to determine the influence of the main process parameters on the strength of the joints. These test results were also employed to calibrate the empirical model. A numerical FE model was developed to predict the temperature distribution at the metal-polymer interface by varying laser power, scanning speed, and beam shape. From results, it was observed that the proposed methodology is capable to predict with good accuracy the strength of the joints under the assumed conditions. The onset of defects in the joint and the local strength can also be predicted. Results indicate that this approach can be readily employed for the optimization of the process conditions as well as the optimization of the laser beam shape and dimension. A similar approach can be easily extended to other processes, where the objective is to produce uniform thermal fields, such as laser welding and hardening.