Many efforts have been made at attaining direct joint between metals and polymers. Laser welding of dissimilar materials is a promising method to bond metals and polymers. In this study, we have developed a finite element (FE) model using ABAQUS software to investigate thermal phenomena of the laser welding of Ti to polyimide. Cylindricalinvolution- normal (CIN) heat source model is used to describe heat source power distribution. The Fortran software is used to programme the CIN heat source model and is linked to ABAQUS. The validation of the FE model is confirmed by attaining the analogous results to experimental data. The design of experiments (DOE) approach is utilized to statistical analysis of laser welding of Ti to polyimide. The effects of laser power (0.5 to 1.5 W) and laser scanning speed (50 to 150 mm/min) on average bond width and delta bond width have been investigated via response surface methodology (RSM). The analysis is designed based on central composite design (CCD) full replication with two factors five levels. Results reveal that laser power is the most significant variable on average bond width and the laser scanning speed is the most influential variable on delta bond width.
