INNOVATION | JOINING AND ASSEMBLY


Right: Covestro worked with Leister Technologies in a laser welding application for fluid-cooled battery


modules used in EVs


the Novolas workstation laser welding system (WS-AT), which it describes as an all-inclusive, ready-to-use, Class 1 solution that can be customised for many component-assembly applications. Lanxess has also been upping its game in materials suitable for laser welding, including EV batteries, and also smaller applications. It says that as miniaturisation of E&E components continues, the potential for use of laser transmission welding is growing, since laser welding allows complex geometries to be produced in a cost-efficient and resource-friendly manner. Last year, the company added


three new products to its selection of LT (laser-transparent) Durethan polyamides and Pocan polybutylene terephthalates (PBT). Claudia Dähling, an expert in technical plastics at the company, says potential applications include components for EV drives and driver assistance systems as well as devices for the Internet of Things. Pocan B3233XHRLT is a 30% glass fibre-


Below: PolyOne has launched a laser weldable PA66


compound in Asia


reinforced PBT that performs well in hot and humid environments, as demonstrated in the SAE/ USCAR-2 Rev. 6 long-term tests of the American Society of Automotive Engineers. “Materials like these are almost unprecedented on the market because standard additives for hydrolysis stabilisation generally cause the laser transparency of PBT to deteriorate significantly,” Dähling says. Most flame retardants also diminish the laser


transparency of thermoplastics, Dähling adds. “With Durethan BKV30FN04LT, we can offer a corresponding compound based on PA6,” she says. It uses a halogen-free flame-retardant package that gives the compound a UL 94 V-0


rating. It leaves hardly any deposits in the tool and provides a high tracking


resistance of 600V (CTI A, Comparative Tracking Index, IEC 60112), making it well suited for components for high-voltage


batteries and plugs. Pocan TP150-002 is a 30% glass


fibre-reinforced PBT compound exhibiting a laser transmission (980nm) of 13%, which Dähling says is around double the transparency of most other laser-transparent PBT product types. In May, PolyOne launched into


the Asian market a new Bergamid laser weldable PA66 compound for use in automotive parts, consumer goods and medical devices. The company says the new addition to its Bergamid portfolio


has controlled laser transmission rates, multiple colour choices and can have customised performance options, allowing manufacturers to produce high performance parts with durable welds and smooth surfaces.


“Laser welding is technically advanced, and its success depends on the weldability, transmission rates, softening point, absorption agents, and colour compatibility of the materials used,” said Flight Xu, General Manager of Specialty Engineered Materials Asia for PolyOne. “Our new Bergamid grades allow high welding strength and a smooth surface resulting in an unparalleled finished product.” PolyOne says it also offer services including part


design, material compatibility evaluation, and laser welding process selection to support manufacturers using its new materials. Akro-Plastic is another materials supplier with a


range aimed at laser-weldable parts. It offers polyamide compounds based on PA6, 66 and 612, unreinforced and reinforced with up to 60% glass fibres, black or coloured and even impact modified. It even has a long fibre reinforced grade, Akromid C28 LGF 40 6 XTC LT schwarz (7176), a PA66/6 with 40% reinforcement, aimed at housing applications in the automotive sector.


More medical options Apart from automotive, medical is also an important area where laser welding has important advantages. At last year’s Medical Design & Manufacturing West show in Anaheim, US, Clariant introduced Mevopur- branded materials incorporating additives to


32 INJECTION WORLD | May 2020 www.injectionworld.com


IMAGE: COVESTRO


IMAGE: POLYONE


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