Thermal experimentation and finite element modeling of laser through transmission welding of PA6 and PA66

This research focuses on laser through transmission welding of thermoplastic materials, experimentation of thermoplastics through transmission laser welding, and a comparison with finite element (FE) modeling of the laser welding process. Thermoplastic through transmission laser welding is increasingly used in industry and manufacturing due to the precise weld location, speed of process, and quality of weld. However, thermoplastic welding parameters are often unknown or thermoplastic welding standards are undeveloped. The comprehensive objective of the experimentation and FE modeling performed in this work is to develop a relationship between melt temperature and laser energy absorption used in thermal welding of PA6 and PA66. Surface exposure experiments are performed on PA6 and PA66 samples to measure thermal profiles. FE simulations of the surface exposure testing and through transmission are completed in Abaqus to simulate the moving heat source of the laser. This work develops a novel experimental testing procedure for studying the thermal properties of PA6 and PA66 thermoplastic materials under surface exposure loading from laser energy. The significant results of this work include experimental development of surface exposure testing for PA6 and PA66 as well as a comparison between maximum temperature measurements in experimentation, simulation, and literature values for PA6 and PA66.