A high-power diode laser (HPDL) was used to weld high-density polyethylene (HDPE) sheets. Laser-welded joints were fabricated with different values of laser power and scan speed. Hot-tool welding was also employed to fabricate joints to make a comparison between this consolidated technology and HPDL welding. Initially, laser heating tests were carried out to study the laser-material interaction. Furthermore, welding tests were carried out and tensile mechanical tests were performed to characterize joints and sound specimens. A similar material behavior was recognized for all the specimens. While the laser process resulted in lower strength and ductility, in comparison to the tool-welding process, the aesthetics of the laser-welded joints were remarkable. The best values of the process parameters were individuated for the laser welding and were used to fabricate a closed structure having sharp edges. The same geometry cannot be obtained by any other welding technology.
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