Experimental analysis of laser assisted joining of Al-Mg aluminium alloy with Polyetheretherketone (PEEK)

Abstract The work is aimed at understanding the influence of process parameters of Laser Assisted Joining of Al-Mg alloy with Polyetheretherketone (PEEK) on the mechanical behavior of the joints. Experimental joining tests were performed by means of a diode laser, with maximum power of 200 W. Laser texturing was performed on the aluminium substrate before joining. These joints exploited the penetration of the aluminium teeth (produced by texturing) into the polymer surface. Laser spot joints were produced by varying the laser beam power and supplied energy. The temperature distribution was monitored during the joining process by means of IR camera. Mechanical characterization tests, based on single lap shear tests, were conducted. Fracture surface analysis was carried out by means of optical microscopy. Different fracture modes were observed depending on the amount of penetration and the presence of bubbles at the substrates interface. The maximum strength of the joints was obtained for P = 200 W and E = 2000 J. Under these conditions, the average strength reached 30 MPa, corresponding to 53% of the PEEK shear strength.