Abstract
Individual mobility is in the process of transformation to electric drives. In the manufacturing process of hairpin windings rectangular copper wires must be contacted. Therefore, high laser power and high welding speed are used in combination with small geometric shapes. For these reasons, the geometric accuracy at different welding speeds is investigated on two optical setups. Furthermore, the process-related deflection of the laser beam must be considered. The method developed in this paper allows to visualize the welding path in the welded position. It is shown, that above a certain deflection, the F-Theta optics lead to an aberration of the focal point in the application plane. This results in a lower energy input. Computed tomography is used to demonstrate this effect and its impact on the cross-sectional area of welded hairpins. For both optical setups, a reduction of the path geometry dimensions can be observed with an increasing welding speed.
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