Laser transmission welding of aluminum film coated with heat sealable co-polyester resin with polypropylene films for applications in food and drug packaging

Abstract The present work deals with the high-power diode laser joining process of aluminum films coated with a polyester resin with polypropylene (PP) films. The first part of the work focused on analyzing the coating process of aluminum films with a polyester resin, using an automatic applicator. The second part of the work was focused on the analysis of the laser joining process of coated aluminum films with plastic counterparts made of PP. Different thicknesses and colors of the PP parts were tested in order to analyze the joining process under a wide range of different conditions. The experimental plan involved the study of the influence of the laser joining parameters, in particular the scanning speed and beam power, on the joints. The joints between aluminum and PP films were subsequently tested by means of tensile and peel-off tests. All the joints between aluminum and PP are obtained through the so-called laser transmission welding (LTW) mechanism. Analysis of the mechanical response of the welded joints allowed to identify the optimal processing window, that is, the choice of the operational parameters that leads to satisfactory welded joints, stating the high potential of laser systems in the joining process of aluminum and PP films for food packaging applications.