Abstract
High demanding novel laser welding applications are currently encountered in e-mobility sector such as overlap joint of thin aluminium alloys without full penetration for battery coolers and battery boxes. In this work, high dynamic laser profiles enabled by unique CIVAN proprietary Coherent Beam Combining (CBC) and Optical Phase Array (OPA) technologies are explored. Experimental investigation of overlap welding of 3003 aluminium alloy plates of 0.8mm thickness at speeds over 10m/min and the study of main process parameters, various beam shapes and oscillation patterns at high frequency up to MHz are undertaken. Effects of laser beam intensity profiles, oscillation frequencies in resulting seam shapes are presented. Process optimization is carried out in terms of weld seam geometry width and depth of penetration avoiding defects as porous, cracks and voids in the interface. Quality of weld joints is evaluated by cross sections macrographs and metallographic examination.
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