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Dissimilar materials laser spot joining between polyethylene terephthalate (PET) and aluminum alloy (A5052) was studied by using pulse YAG laser. The results showed that it was possible to make a joint in a wide range of heat input. Molten pool was formed at the interface of A5052 and depth of molten pool increased with increase in heat input. Tensile shear test was carried out to evaluate strength of the joints. The result showed that tensile shear strength increased with increase in the heat input when the molten pool filled with molten or softened PET. On the other hand, instability of joining state inside the molten pool might induce variation in the strength. FEM analysis was carried out to investigate effect of molten pool shape on the strength. The result showed that molten pool radius did not significantly affect tensile shear strength. In contrast, the joint strength increased with increase in the molten pool depth as observed in result of the experiment. It is proposed that taking into account the mechanical effect such as molten pool shape is an important approach to improve the joining strength under tensile shear loading.

Effect of Molten Pool Shape on Tensile Shear Strength of Dissimilar Materials Laser Spot Joint between Plastic and Metal