Semiempirical, squeeze flow, and intermolecular diffusion model. II. Model verification using laser microwelding

This article reviews the application of a coupled squeeze flow and intermolecular diffusion model, which was used to predict the quality and size of microwelds in plastics. Weld widths predictions were compared with previously presented experimental results using moving heat source models and temperature fields. The motivation for this work was to develop and verify a model based on fundamental principles that could accurately predict weld size and strength for conventional plastic welding techniques as well as novel techniques such as laser microwelding. It is envisioned that the resulting model could be used to predict proper welding parameters, including laser power and travel speed, to produce welds of varying size. Although insight into weld quality can be derived from this model, it was not the goal of this work to accurately predict weld strength for laser microwelding because of the difficulty in measuring weld strength on the micron scale. However, as reported in Part 1, weld strength for impulse welds were accurately predicted. In this model it was found that variable temperature histories, rather than a single value of maximum weld temperature, allows more accurate modeling of the welding process. In this work (Part 2), microwelds as small as 11 μm in width were produced with transmission infrared welding. In addition, welds over 150‐μm wide were also generated and the model was able to predict the range of weld widths that were found experimentally. It was found that the predictions were in very good agreement with the experimental results. There was some deviation between the experimental data and the model at the extreme parameters and it is believed that this was due to the temperature‐dependent material properties as well as optical aberrations. POLYM. ENG. SCI., 2008. © 2008 Society of Plastics Engineers