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

Abstract

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.