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Laser welding experiments involving amorphous thermoplastic polymer (PMMA) and 304 austenitic stainless steel plates were conducted to explore the influence of laser welding process parameters on plastic–metal joints. A high-speed camera was applied to record the dynamics of the molten pool and the formation of bubbles to reveal the bonding mechanisms of the hybrid joints. The influence of process parameters on the joints was analyzed using temperature measurements performed with thermocouples. The microstructure morphology of joints was observed using SEM. The mechanical characterization of the hybrid joints was carried out to understand the effect of the welding conditions on the weld morphology, flaws and shear stress. Different interface temperatures resulted in two types of bubbles and led to different weld morphology characteristics. A stable hybrid joint with the best shear stress was produced with a laser line energy of 20.16 J/mm2, a temperature of 305 °C and small bubbles. The shear stress of the effective joint under the maximum mechanical resistance was 4.17 MPa. The chemical bonds (M-O, M-C) and mechanical anchoring that formed on the steel’s surface contributed to the joint bonding. Range analysis provided guidance for identifying the impact of individual factors in the shear stress for the laser welding of plastic–metal.

Interface Formation and Bonding Mechanisms of Laser Welding of PMMA Plastic and 304 Austenitic Stainless Steel