Fig. 1. Schematic of TC4/CFPEEK laser joining

Fig. 2. Microstructures of CFPEEK. (a) Surface; (b) cross section

Fig. 3. Finite element model. (a) Three-dimensional model; (b) CFPEEK grid division; (c) TC4 grid division

Fig. 4. Temperature field of weld centerline section (P=3500 W,v=15 mm/s)

Fig. 5. Comparison between experimental depth and simulated melting depth for TC4 (left) and CFPEEK (right) (P=3500 W). (a) v=10 mm/s; (b) v=15 mm/s; (c) v=20 mm/s

Fig. 6. Actual melting area on CFPEEK surface and corresponding temperature field cloud image (P=3500 W). (a) Surface morphology of CFPEEK at fracture of laser joint; (b) v=10 mm/s; (c) v=15 mm/s; (d) v=20 mm/s; (e) v=25 mm/s; (f) v=30 mm/s; (g) v=35 mm/s

Fig. 7. Experimental and simulated resin melting width on CFPEEK surface

Fig. 8. Temperature fields of TC4 and CFPEEK under different laser powers (v=25 mm/s)

Fig. 9. Melting depths of TC4 and CFPEEK under different laser powers (v=25 mm/s)

Fig. 10. Temperature distributions of resin on CFPEEK surface. (a) Schematic of temperature data extraction; (b) temperature distributions of resin on CFPEEK surface under different laser powers (v=25 mm/s)

Fig. 11. Temperature fields under different welding speeds (P=3500 W)

Fig. 12. Melting depths of TC4 and CFPEEK under different welding speeds (P=3500 W)

Fig. 13. Temperature curves of nodes located at welding centerline on CFPEEK surface under different welding speeds (P=3500 W)

Fig. 14. Temperature distributions of resins on CFPEEK surface along lap width direction under different welding speeds (P=3500 W)

Fig. 15. Temperature curves of nodes located at welding centerline on CFPEEK surface under different beam sizes (P=3500 W, v=20 mm/s)

Fig. 16. Temperature distributions of resins on CFPEEK surface along lap width direction under different beam sizes (P=3500 W, v=20 mm/s)

Fig. 17. Laser joining process window for TC4 and CFPEEK