Fine-tuned Remote Laser Welding of Aluminum to Copper with Local Beam Oscillation

Fetzer, Florian; Jarwitz, Michael; Stritt, Peter; Weber, Rudolf; Graf, Thomas

doi:10.1016/j.phpro.2016.08.047

Cited by 42 publications

(13 citation statements)

References 7 publications

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“…Different approaches in order to join aluminium and copper-especially via laser welding-are presented in the literature. While Weigl et al [14] and Gillner et al [15] used process variations like adapted filler wire or high brilliance laser, respectively, Fetzer et al [16] obtained a reduced weld penetration of the upper copper sheet in lap joints by beam oscillation. Schmalen et al [17] presented a modified laser brazing process with a pulsed laser equipment, where the lower copper sheet remains solid and the resultant IMC formation can be reduced to avoid significant interface embrittlement.…”

Section: Introductionmentioning

confidence: 99%

Influence of Pin Length and Electrochemical Platings on the Mechanical Strength and Macroscopic Defect Formation in Stationary Shoulder Friction Stir Welding of Aluminium to Copper

Regensburg

Schürer

Weigl³

et al. 2018

Metals

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Abstract:The fabrication of dissimilar joints for electrical applications raises challenges for conventional joining technologies. Within solid-state processes, friction stir welding (FSW) provides numerous advantages to realize different joint configurations. However, depending on the intermixing of the materials, defects like hooking and significant intermetallic compound formation around copper fragments are observed and lead to a decrease in joint properties. Therefore, stationary shoulder FSW was applied to produce 2 mm EN AW1050/CW024A lap joints with minimized intermixing at the interface. Compared to conventional FSW, the range of the friction-based heat input can be increased without risking excessive plastification under the tool shoulder. The influence of the pin length on the interfacial structure as well as the mechanical properties were investigated. A pin length of 2.2 mm and hence a plunging of approximately 0.2 mm into the lower copper sheet was found to obtain the highest failure load. A further increase caused the formation of hooking defects, which led to void formation at the interface and failure within the area of the thinned aluminium sheet. The results were also transferred to lap joints with a tin and silver interlayer of 10 µm and also showed good results in terms of bond strength and contact area.

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Section: Introductionmentioning

confidence: 99%

Influence of Pin Length and Electrochemical Platings on the Mechanical Strength and Macroscopic Defect Formation in Stationary Shoulder Friction Stir Welding of Aluminium to Copper

Regensburg

Schürer

Weigl³

et al. 2018

Metals

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show abstract

“…The variation of the laser power for each weld are shown in Table 3. Besides, the wobbling technique is applied in this study as it has been proved to enhance the weld quality in literature [31], [32]. The thin sheets of Al and copper having thickness of 0.27∽0.3 mm has been employed as welding specimens in the experiment.…”

Section: Methodsmentioning

confidence: 99%

A Parametric Study on Dissimilar Metal Welding of Aluminum and Copper using Pulsed Fiber Laser

Trinh

Chatterjee

Lee

2021

Preprint

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Joining dissimilar metals is critically challenging due to the difference in properties of the metals themselves which leads to the formation of brittle intermetallic compounds (IMCs). Aluminum (Al) and copper (Cu) are well-known materials for electrical application as they attribute to various advantageous characteristics. In lithium-ion batteries, to obtain most of the features of the metals, combinations of these metals are highly recommended. However, with such high reflective metals and heat-sensitive characteristics in the battery, the joint of these metals needs to be processed with an advanced method. In this study, a pulsed fiber laser source that suits to process for heat-sensitive components is utilized to weld two overlap configurations of Al/Cu and Cu/Al, separately. Different ranges of laser power are designated for each welding configuration separately. Thus, the quality of the two welds is evaluated in terms of microstructure and mechanical properties. Consequently, it is found that the growth of IMCs with dendritic structure towards the Al side is observed in both cases. Moreover, the weld of Al/Cu shows a better connection strength as well as fewer imperfections than the weld of Cu/Al.

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“…dynamic redistribution of the energy, for example for remote laser welding without filler material [2]. Static beam shaping is another possibility to modify the energy input from a laser beam into the material that allows the optimization of not only the conditions of pre and post-heating but also the spatial intensity distribution in the process zone.…”

Section: Joerg Volpp and Alexander Laskinmentioning

confidence: 99%

Beam shaping solutions for stable laser welding

Volpp

Laskin²

2021

PhotonicsViews

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The laser beam is a highly flexible tool that is used for many material processing applications. New spatial beam shaping technology enables even further functionality to create up to four focal spots in an axial or lateral direction, which enables the distribution of the energy to be tailored. It was shown that certain beam shapes help to suppress spattering and increase the bridgeable gap size during deep penetration laser welding.

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Fine-tuned Remote Laser Welding of Aluminum to Copper with Local Beam Oscillation

Cited by 42 publications

References 7 publications

Influence of Pin Length and Electrochemical Platings on the Mechanical Strength and Macroscopic Defect Formation in Stationary Shoulder Friction Stir Welding of Aluminium to Copper

Influence of Pin Length and Electrochemical Platings on the Mechanical Strength and Macroscopic Defect Formation in Stationary Shoulder Friction Stir Welding of Aluminium to Copper

A Parametric Study on Dissimilar Metal Welding of Aluminum and Copper using Pulsed Fiber Laser

Beam shaping solutions for stable laser welding

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