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Laser direct joining of carbon fiber reinforced thermoplastic (CFRTP) composite plate and titanium alloy plate with a thickness of 2 mm was performed with swing laser. Numerous air bubble of submillimeter size were observed inside the fusion zone of CFRTP and titanium alloy at the cross section of the joints. The air bubble characteristics were analyzed based on the morphology and size, while the formation mechanism of air bubble was further elucidated according to the nucleation mode, nucleation site and nucleation position. The results demonstrated that the nucleation modes of air bubble are substantially divided into homogeneous nucleation and heterogeneous nucleation, which is related to the nucleation sites. The nucleation mode presents a crucial factor influencing the position and morphology of air bubble. In addition, the air bubble characteristics are also determined by the clamp pressure and resin flow. The final morphology of air bubble is primarily represented by four typical types.

Study on bubble morphology at interface of laser direct joint between carbon fiber reinforced thermoplastic (CFRTP) and titanium alloy