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Journal of Engineering
Volume 2014, Article ID 197060, 9 pages
http://dx.doi.org/10.1155/2014/197060
Research Article
Optimization of Laser Transmission Joining Process
Parameters on Joint Strength of PET and 316 L Stainless
Steel Joint Using Response Surface Methodology
Shashi Prakash Dwivedi and Satpal Sharma
Gautam Buddha University, Greater Noida, Gautam Buddha Nagar, Uttar Pradesh 201310, India
Correspondence should be addressed to Shashi Prakash Dwivedi; shashi gla47@rediffmail.com
Received 8 July 2014; Accepted 8 September 2014; Published 29 September 2014
Academic Editor: Jose M. Guisan
Copyright 2014 S. P. Dwivedi and S. Sharma. This is an open access article distributed under the Creative Commons Attribution
License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly
cited.
The objective of the present work is to study the effects of laser power, joining speed, and stand-off distance on the joint strength of
PET and 316 L stainless steel joint. The process parameters were optimized using response methodology for achieving good joint
strength. The central composite design (CCD) has been utilized to plan the experiments and response surface methodology (RSM)
is employed to develop mathematical model between laser transmission joining parameters and desired response (joint strength).
From the ANOVA (analysis of variance), it was concluded that laser power is contributing more and it is followed by joining speed
and stand-off distance. In the range of process parameters, the result shows that laser power increases and joint strength increases.
Whereas joining speed increases, joint strength increases. The joint strength increases with the increase of the stand-off distance
until it reaches the center value; the joint strength then starts to decrease with the increase of stand-off distance beyond the center
limit. Optimum values of laser power, joining speed, and stand-off distance were found to be 18 watt, 100 mm/min, and 2 mm to
get the maximum joint strength (predicted: 88.48 MPa). There was approximately 3.37% error in the experimental and modeled
results of joint strength.
1. Introduction
Laser transmission joining has various advantages over
conventional plastic joining techniques, for example, no
contact, high joining speed, accuracy, flexibility, small heat
affected zone, and so forth. Laser transmission joining technology has extensively promising applications in the fields
of the microfluidics, microelectromechanical systems, and
biomedicine [1, 2]. During laser transmission welding of overlap connections laser radiation transmits through the upper
thermoplastic part and is absorbed by a lower material. Heat
is developed in the laser absorbing part, which melts the thermoplastic locally. Due to heat conduction, the laser transparent part melts locally too. Thermoplastic materials are laser
radiation absorbing, when the material contains, for example,
carbon black, absorbing additives, and pigments or when
the materials are reinforced with carbon fibers [3]. There is
a continuously growing interest in the joining of dissimilar
Journal of Engineering
Table 1: Chemical composition and mechanical properties of 316 L stainless steel (% wt.).
Chemical composition (% wt.)
C
0.03
Mn
Si
Cr
Ni
Mo
Fe
0.045
0.03
0.7
16
12
2.8
0.1
Balance
Mechanical properties
UTS
Hardness
(MPa)
(Rockwell)
558
B79
Scanning laser
Clamping
forces
Transparent
joining (PET)
Cover glass
Absorbing joining
material (316 L)
Clamping
forces
Input parameters
Power (watt)
Joining speed (mm/min.)
Stand-off distance (mm)
Range
1418
100200
13
(1)
(2)
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3
Table 3: Design matrix and experimental results.
Standard order
18
1
3
8
9
15
6
17
19
14
16
4
13
5
12
2
20
7
11
10
Run order
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Power (watt)
16
14
14
18
12.64
16
18
16
16
16
16
18
16
14
16
18
16
14
16
19.36
1 mm
(a)
1 mm
(b)
1 mm
1 mm
(c)
(d)
Figure 2: Macrostructure of joint seam width of 316 L stainless steel and PET joint.
= (1 , 2 , . . . , ) .
= + 1 1 + 2 2 + 12 1 2 .
(3)
(4)
(5)
Journal of Engineering
(a)
150 m
150 m
150 m
(b)
150 m
150 m
150 m
(d)
(c)
(e)
(f)
Figure 3: Microstructure of joint seam width of 316 L stainless steel and PET joint.
Journal of Engineering
5
Table 4: Analysis of variance (ANOVA) for joint strength.
Source
Sum of squares
Model
(power)
(joining speed)
(stand-off distance)
2
2
2
Residual
Lack-of-fit
Pure error
Cor. total
Std. dev.
Mean
C.V. %
PRESS
2900.84
1281.26
634.37
53.67
3.46
4.26
15.18
26.85
57.11
883.86
3.08
2.14
0.94
2903.92
0.56
80.84
0.69
17.60
DF
Mean square
value
9
1
1
1
1
1
1
1
1
1
10
5
5
19
322.32
1281.26
634.37
53.67
3.46
4.26
15.18
26.85
57.11
883.86
0.31
0.43
0.19
1046.19
4158.79
2059.06
174.22
11.23
13.84
49.27
87.15
185.38
2868.89
value
Prob. >
<0.0001
<0.0001
<0.0001
<0.0001
0.0074
0.0040
<0.0001
<0.0001
<0.0001
<0.0001
2.27
0.1942
-squared
Adj. -squared
Pred. -squared
Adeq. precision
Significant
Not significant
0.9989
0.9980
0.9939
103.941
Predicted
90.71
99
2
80.51
70.31
95
90
80
70
50
30
20
10
5
1
60.11
60.11
70.31
80.51
Actual
90.71
100.91
0.34123 Power2
7.96289 004 Joining speed2
7.83143 Stand-off distance2
6.57500 003 Power Joining speed
0.36500 Power Stand-off distance
0.027550 Joining speed
Stand-off distance.
(6)
The model adequacy is inspected by evaluating the
residuals (difference between observed and fitted value of
response). If the model is acceptable, the residuals should be
2.29
1.30
0.32
0.67
Studentized residuals
1.66
Journal of Engineering
18.00
14.00
100.00
Power = 17.99
200.00
1.00
3.00
Desirability = 1.000
100.36
60.59
Figure 6: Ramp function graph for maximum joint strength with desirability one.
100.36
90.4175
100.36
80.475
70.5325
90.4175
80.475
70.5325
60.59
60.59
14.00
15.00
16.00
17.00
18.00
100.00
125.00
A: laser power
(a)
150.00
175.00
B: joining speed
200.00
(b)
100.36
90.4175
80.475
70.5325
60.59
1.00
1.50
2.00
2.50
C: stand-off distance
3.00
(c)
Figure 7: Single factor effect of laser power, joining speed, and stand-off distance on joint strength.
Journal of Engineering
7
Joint strength (MPa)
200.00
74.7809
102.283
94.0326
85.7819
77.5311
69.2504
B: joining speed
Pa)
Joint strength (M
175.00
80.2814
85.7819
6
150.00
91.2623
96.7828
125.00
200.00
18.00
175.00
B:
joi
17.00
150.00
16.00
wer
125.00
r po
15.00
e
s
a
A: l
pe
100.00 14.00
ed
nin
gs
100.00
14.00
15.00
16.00
17.00
18.00
A: laser power
(a)
(b)
Figure 8: Interaction effect of laser power and joining speed on the joint strength. (a) 3D interaction; (b) the contour plot.
96.848
89.3573
81.8666
74.3759
66.8852
C: stand-off distance
(M
Joint strength
Pa)
3.00
3.00
C:
18.00
2.50
17.00
2.00
sta
16.00
ndr
1.50
off
owe
15.00
er p
dis
s
a
l
1.00 14.00
tan
A:
ce
(a)
2.50
2.00
80.2814
85.7819
91.2823
1.50
74.7809
1.00
14.00
15.00
16.00
17.00
18.00
A: laser power
(b)
Figure 9: Interaction effect of laser power and stand-off distance on the joint strength. (a) 3D interaction; (b) the contour plot.
Journal of Engineering
Table 5: Confirmation experiment table.
Responses
Joint strength
Experiment number
Experiment value
(MPa)
Average of
experimental value
(MPa)
Predicted value
(MPa)
1
2
3
87.6
94.5
92.6
91.56
88.48
C: stand-off distance
Pa)
(M
Joint strength
3.00
C:
3.37%
3.00
93.6635
88.057
82.4505
76.844
71.2374
Percentage variation
74.7809
2.50
91.2823
6
2.00
85.7819
1.50
200.00
2.50
175.00
2.00
sta
150.00
ndeed
1.50
off
g sp
125.00
dis
inin
o
j
tan
1.00 100.00
:
B
ce
80.2814
1.00
100.00
74.7809
125.00
(a)
150.00
B: joining speed
175.00
200.00
(b)
Figure 10: Interaction effect of joining speed and stand-off distance on the joint strength. (a) 3D interaction; (b) the contour plot.
4. Conclusions
The following conclusions can be drawn from the analysis.
(1) Laser transmission joining can be adapted favorably
for the joint between PET films and 316 L stainless
steel.
(2) Microstructure of the welded joint revealed good
bond between PET films and 316 L stainless steel and
very less amount of cavity and vaporization observed.
(3) Within the laser transmission joining process parameters range, as the laser power increases, the joint
strength also increases, while the joint strength
decreases with increased joining speed. On the other
hand, the joint strength increases with the increase of
the stand-off distance until it reaches the center value;
Journal of Engineering
the strength then starts to decrease with the increase
of stand-off distance beyond the center limit.
(4) The maximum value of joint strength with desirability one was obtained: 100.531 MPa at laser power
of 17.99 watt, joining speed of 102.28 mm/min, and
stand-off distance of 1.69 mm.
(5) Within the laser transmission joining process parameters the optimum parameters for joint strength were
found to be higher laser power (18 watt), lower joining
speed (100 mm/min), and mid value of stand-off
distance (2 mm). The predicted value of joint strength
was found to be 88.48 MPa at 95% confidence interval. There is only 3.37% error in the experimental and
modeled results.
Conflict of Interests
The authors declare that there is no conflict of interests
regarding the publication of this paper.
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