Abstract
Spatial beam oscillation during laser beam welding of aluminum to copper was investigated. The beam was spatially oscillated perpendicular to the direction of feed in a sinusoidal mode. The influence of the oscillation amplitude and frequency on the weld seam geometry and the implications on the electrical resistance of the joints was investigated. It was found that spatial beam oscillation allows to set the welding depth and seam width virtually independent of each other. Furthermore, low welding depths into the lower copper sheet in combination with high ratios of seam width at the interface of the two sheets to welding depth into the lower copper sheet result in low electrical resistances of the welds. Low electrical resistances were found to correlate with high mechanical strengths of the welds.
Highlights
Joining of aluminum (Al) to copper (Cu) is required for high-power, light-weight electrical applications, such as e-mobility or battery applications [1,2]
In contrast to the using findings summarized in this inless) this and paper focus on reproducible joining aluminum to copper multi-mode lasers withsection, high the investigations presented in this paper focus on reproducible joining of aluminum to copper power in combination with spatial beam oscillation
For the used material thickness of this means that weld seam widths >1 mm are required at welding depths of about 1 mm
Summary
Joining of aluminum (Al) to copper (Cu) is required for high-power, light-weight electrical applications, such as e-mobility or battery applications [1,2]. Cu is challenging due to the formation of intermetallic phases in the weld seam [3] and the strongly differing thermophysical properties of the two materials, such as the melting temperature and the heat conductivity. A strong mixture of the materials and the formation of intermetallic phases in the weld seam is common [5]. The use of a spatial oscillation of the laser beam has proven to be a suitable measure to stabilize the welding process, especially the welding depth. A stabilization of the welding depth against focal shift by the use of spatial beam oscillation has been observed [7]. Homogeneous mixing of the two materials in the weld seam was demonstrated using a single-mode fiber laser and spatial beam oscillation [8]. Large joining widths at the interface and low penetration depths into the lower Cu sheet
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