Abstract
Laser beam welding of aluminum and copper (Al-Cu) materials is a cost efficient joining technology to produce e.g. connector elements for battery modules. Distortion low connections can be achieved, which have electrical favorable properties. Numerical simulation of the laser beam welding process of Al-Cu dissimilar materials can provide further insight into principal process mechanisms and mechanical response of the joint parts. In this paper a methodology is introduced to investigate the structural behavior of Al-Cu joints in overlap joint with respect to welding distortions and residual stresses. First the material model of the homogeneous base materials are validated. Next, a generic material model approach is used to simulate the structural behavior of heterogeneous Al-Cu connections.
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