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<p>Laser-assisted metal-polymer (LAMP) joining is a promising technique for fabricating hybrid metal-polymer joints using a laser beam as the heating source. This study presents a detailed comparison of transmission and conduction modes in LAMP joining of polyethylene terephthalate (PET) and AISI 1018 low-carbon steel, employing a 1&#xa0;kW fiber laser system. Systematic experiments and regression analyses are used to develop parameter–quality correlation models, enabling direct comparison of the two modes by normalizing process windows. Results show that approximately 14% higher peak weld strength and wider seams are achieved by conduction mode compared to transmission mode, with broader process windows and peak joint performance occurring at similar line energies. Weld strength in both modes peaks at high power and scanning speed, with an optimal defocus distance and moderate weld passes maximizing quality. Interfacial characterization using optical and electron microscopy and energy-dispersive x-ray spectroscopy confirms continuous, void-free bonding with mixed adhesive–cohesive failure and effective mechanical interlocking at the PET–steel interface. X-ray photoelectron spectroscopy reveals localized chemical interactions, including metal–carbide (M–C) bonding at 283.4–283.6&#xa0;eV and metal–oxygen (M–O) bonding at 530.9&#xa0;eV. These findings establish clear process–property relationships, highlighting conduction mode as the superior LAMP joining mode for reliable, high-strength hybrid PET–AISI 1018 joints.</p>

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Laser-Assisted Steel–PET Joining: Comparative Analysis of Transmission and Conduction Modes and Interfacial Bonding Mechanisms

  • 期刊论文

  • 发表日期：

    2025年10月15日

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  • Purushottam Kumar,
  • Bappa Acherjee,
  • Joyjeet Ghose,
  • Somnath Chattopadhyaya

摘要

Laser-assisted metal-polymer (LAMP) joining is a promising technique for fabricating hybrid metal-polymer joints using a laser beam as the heating source. This study presents a detailed comparison of transmission and conduction modes in LAMP joining of polyethylene terephthalate (PET) and AISI 1018 low-carbon steel, employing a 1 kW fiber laser system. Systematic experiments and regression analyses are used to develop parameter–quality correlation models, enabling direct comparison of the two modes by normalizing process windows. Results show that approximately 14% higher peak weld strength and wider seams are achieved by conduction mode compared to transmission mode, with broader process windows and peak joint performance occurring at similar line energies. Weld strength in both modes peaks at high power and scanning speed, with an optimal defocus distance and moderate weld passes maximizing quality. Interfacial characterization using optical and electron microscopy and energy-dispersive x-ray spectroscopy confirms continuous, void-free bonding with mixed adhesive–cohesive failure and effective mechanical interlocking at the PET–steel interface. X-ray photoelectron spectroscopy reveals localized chemical interactions, including metal–carbide (M–C) bonding at 283.4–283.6 eV and metal–oxygen (M–O) bonding at 530.9 eV. These findings establish clear process–property relationships, highlighting conduction mode as the superior LAMP joining mode for reliable, high-strength hybrid PET–AISI 1018 joints.