The efforts of this research were to determine the sensitivity to interfacial gaps in laser transmission welding using various laser welding parameters. Note that the melting of the transparent side of the interface relies mainly on heat conduction from the absorbing side since the laser beam energy is mainly absorbed in the non-transparent material. If a gap exists between the parts at the faying surface, the weld may not form at that location. For this study, interfacial gaps created via manufactured voids were moulded into the components to be welded. After welding, the samples were then assessed using microstructural analysis, fracture surface analysis and hydraulic burst testing. The research has shown laser transmission welding has the potential of obtaining strong welds, exceeding those of linear vibration welds of similar geometry. Surprisingly, very strong bonds were observed even with a large degree of porosity/voids in the weld.
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