Laser welding of dissimilar copper and aluminum sheets by shaping the laser pulses

Mathivanan, Karthik; Plapper, Peter

doi:10.1016/j.promfg.2019.08.021

Cited by 40 publications

(13 citation statements)

References 14 publications

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“…Larger weld seam can be obtained with laser beam oscillation, by maintaining keyhole conditions (10 7 W/cm 2 ) required to weld highly reflective metals like Al and Cu [5]. Oscillated laser beam is beneficial in controlling the depth of penetration into the bottom sheet [6,7]. Welding from Cu sheet is challenging in terms of higher reflectivity, thermal conductivity and melting temperature (1080 • C) in contrast to Al.…”

Section: Introductionmentioning

confidence: 99%

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Welding of Copper to Aluminium With Laser Beam Wavelength of 515 nm

Mathivanan¹,

Plapper²

2021

Preprint

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In laser joining of copper (Cu) and aluminum (Al) sheets, the Al sheet is widely chosen as the top surface for laser irradiation because of increased absorption of laser beam and lower melting temperature of Al in contrast to Cu. This research focus on welding from Cu side to Al sheet. The main objective of irradiating the laser beam from the copper side (Cu on top) is to exploit higher solubility of Al in Cu. A significantly lower laser power can be used with 515 nm laser in comparison to 1030 nm. In addition to low laser power, a stable welding is obtained with 515 nm. Because of this advantage, 515 nm is selected for the current research. By fusion of Cu and Al the two sheet metals are welded, with presence of beneficial Cu solid solution phase and Al+Al2Cu in the joint with the brittle phases intermixed between the ductile phase. Therefore the mixed composition strengthens the joint. However excessive mixing leads to formation of more detrimental phases and less ductile phases. Therefore optimum mixing must be maintained. Energy dispersive X-ray spectroscopy (EDS) analysis indicate that large amount of beneficial Cu solid solution and Al rich phases is formed in the strong joint. From the tensile shear test for a strong joint, fracture is obtained on the heat-affected zone (HAZ) of Al. Therefore the key for welding from copper side is to have optimum melt with beneficial phases like Cu and Al+ Al2Cu and the detrimental phases intermixed between the ductile phases

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Section: Introductionmentioning

confidence: 99%

“…Therefore, to weld from copper side high intensity or good absorption of laser light is a fundamental requirement [8][9][10]. Very less investigations are conducted in the analysis of welding from Cu to Al [7,11,12]. The phase composition and the intermixing of Cu and Al in Cu-Al (Cu on top) configuration is not well studied.…”

Section: Introductionmentioning

confidence: 99%

Welding of Copper to Aluminium With Laser Beam Wavelength of 515 nm

Mathivanan¹,

Plapper²

2021

Preprint

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“…Some research found that the continuous IMCs layer can enhance the metallurgical bonding and then increase the joint strength and ductility 1,2,54 . However, other research found that discontinuous IMCs can increase the joint strength and ductility 3,31 . On the other hand, some investigations found that a planar IMCs layer can increase the conductivity, the strength and ductility of the joints 4,5 .…”

Section: Relationship Between Joint Properties and Interfacial Imcs L...mentioning

confidence: 92%

“…These IMCs can affect the mechanical properties and electrical properties of Al/Cu joints owing to their brittleness and resistivity characteristics. Many works have focused to control the IMCs by optimizing welding process parameters [1][2][3][4][5][6][7] . Inserting a filler material between Al and Cu is one good method to adjust the phase type, thickness and morphology of Cu x Al y 8 .…”

Section: Introductionmentioning

confidence: 99%

Influence of Filler Alloy on Microstructure and Properties of Induction Brazed Al/Cu Joints

2022

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This work aimed to clarity the influence of filler alloy on microstructures and properties of induction brazed Al/Cu joints. It was found that the alloying elements in the filler alloy changed the morphology and phase type of interfacial layer in the joint. Mg converted the native Al 2 O 3 film into MgO and stopped the re-oxidation of aluminum. However, excessive Mg caused planar inter-metallic compounds (IMCs) to become wavy, which decrease the ductility of the joint. A suitable amount of Cu and Si removed residual oxide film and resulted in a thin planar IMCs layer, which is beneficial to Al/Cu joint. Al-8Si-4Cu-2Mg-1Ga-0.05Ce filler foil produced an excellent joint consisting of a 2μm Cu 9 Al 4 /CuAl 2 planar layer and free from oxide film. The tensile strength of the joint is higher than that of aluminum. The bend angle is higher 130°. The electrical resistivity of the joint is lower than the theoretical value.

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“…In the case of the laser pulsed welding, the effect of the pulse shape had a profound effect. The pulse shape with a slight preheating and annealing at the end improved the quality of joints by suppressing cracking and porosity with increased the mixing between Cu and Al [167] for improved strength. Therefore, higher strength may be achieved.…”

Section: Effect Of Welding Parameters On Cu-al Imc Layer and Mechanical Propertiesmentioning

confidence: 99%

A Review on Laser-Assisted Joining of Aluminium Alloys to Other Metals

Bunaziv

Akselsen

Ren

et al. 2021

Metals

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Modern industry requires different advanced metallic alloys with specific properties since conventional steels cannot cover all requirements. Aluminium alloys are becoming more popular, due to their low weight, high corrosion resistance, and relatively high strength. They possess respectable electrical conductivity, and their application extends to the energy sector. There is a high demand in joining aluminium alloys with other metals, such as steels, copper, and titanium. The joining of two or more metals is challenging, due to formation of the intermetallic compound (IMC) layer with excessive brittleness. High differences in the thermophysical properties cause distortions, cracking, improper dilution, and numerous weld imperfections, having an adverse effect on strength. Laser beam as a high concentration energy source is an alternative welding method for highly conductive metals, with significant improvement in productivity, compared to conventional joining processes. It may provide lower heat input and reduce the thickness of the IMC layer. The laser beam can be combined with arc-forming hybrid processes for wider control over thermal cycle. Apart from the IMC layer thickness, there are many other factors that have a strong effect on the weld integrity; their optimisation and innovation is a key to successfully delivering high-quality joints.

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Laser welding of dissimilar copper and aluminum sheets by shaping the laser pulses

Cited by 40 publications

References 14 publications

Welding of Copper to Aluminium With Laser Beam Wavelength of 515 nm

Welding of Copper to Aluminium With Laser Beam Wavelength of 515 nm

Influence of Filler Alloy on Microstructure and Properties of Induction Brazed Al/Cu Joints

A Review on Laser-Assisted Joining of Aluminium Alloys to Other Metals

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