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This paper aims to investigate the bonding mechanism during laser transmission welding of polycarbonate sheets using an electrolytic iron powder (EIP) absorber. The experiments are performed at different scan speeds and laser powers. The mechanical strength is determined by the lap shear test. The influence of line energy, interface temperature, and absorptivity on weld strength is discussed. The weld characteristics, bond morphology, and elemental distribution at the cross-section and fracture interface of the welded samples are analyzed. The results show that the maximum breaking strength of 1180 N is obtained at the 400 mm/min scan speed and 100 W laser power. The iron particles are observed mechanically interlocked at the lowest line energy with partial chemical bonding. However, the chain diffusion and chemical bonding have been increased with line energy. Thermal degradation and burning of the polycarbonate at the interface restrict the bonding and reduces the weld strength.

Mechanism of bonding during laser transmission welding using EIP absorber