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

Mathivanan, Karthik; Plapper, Peter

doi:10.20944/preprints202108.0443.v1

Cited by 4 publications

(6 citation statements)

References 13 publications

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“…The distribution of these phases with a combination of ductile and brittle intermetallic structures apparently was achieved with parameter set #5, as the average tensile strength of this parameter set was found to be the highest for the oscillating welds. This outcome confirms the studies in [ 49 ], where this type of oscillation is also found to be beneficial for the distributing of the intermetallic phases, since the fluid flow and the resulting fusion zone follow the trajectory of the laser beam. For the linear stitched weld, a higher maximum tensile load could be achieved in case of #2 with lower line energy.…”

Section: Resultssupporting

confidence: 90%

“…Studies in this direction, using visible wavelengths such as green and blue, are currently less comprehensive in the literature [ 48 ]. Mathivanan et al [ 49 ] investigated the mechanical properties of copper aluminum welds in overlap configuration using a beam oscillation in the form of infinite shape with 515 nm laser radiation. A discontinuous weld seam was observed in cross-sectional direction, which was related to the different degree of intermixing.…”

Section: State Of the Artmentioning

confidence: 99%

“…A discontinuous weld seam was observed in cross-sectional direction, which was related to the different degree of intermixing. The combination of ductile and brittle intermetallic microstructure was found, resulting in a strong joint with large plastic deformation of the aluminum sheet [ 49 ]. The authors in [ 50 ] focused on conduction mode welding using a blue laser for welding low-thickness dissimilar materials, namely nickel-coated copper and mild steel, for electric vehicle battery manufacturing.…”

Section: State Of the Artmentioning

confidence: 99%

“…From the state -of -the -art and the amount of research on this topic, it can be concluded that a deeper understanding of the influencing factors affecting the welding process is absolutely needed and the top plate configuration selection in copper aluminum joining requires methodology. In summary, only limited research has been conducted to study copper as top plate in copper aluminum mixed joints [ 49 ], as for example the investigations in [ 50 , 51 , 52 ]. In addition, the use of visible laser radiation proves high potential for these limited material thicknesses in deep penetration mode to create a reproducible, low fluctuation joint between the two metals.…”

Section: State Of the Artmentioning

confidence: 99%

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Seam Properties of Overlap Welding Strategies from Copper to Aluminum Using Green Laser Radiation for Battery Tab Connections in Electric Vehicles

et al. 2023

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Laser beam welding of metals has progressed dramatically over the last years mainly arising from joining applications in the field of electromobility. Allowing the flexible, automated manufacturing of mechanically, electrically, and thermally stressed components, the process is more frequently applied for joining highly reflective materials, for example for battery tab and busbar connections. The local, non-contact energy input favors this welding technology; however, joining of copper and aluminum sheets still poses a challenge due to the physical properties of the joining partners and intermetallic phases from dissimilar metal interaction, which reduce seam performance. The use of green laser radiation compared to infrared laser radiation offers the advantage of a significantly increased absorptivity for copper materials. A changed incoupling behavior is observed, and a lower deep penetration threshold has been already proven for 515 nm wavelength. When copper and aluminum are welded with the former as top sheet, this welding mode is essential to overcome limited aspect ratios from heat conduction welding. However, the opportunities of applying these beam sources in combination with spatial power modulation to influence the interconnection area of copper-aluminum joints have not yet been studied. The aim of this work is therefore to investigate the seam properties and process stability of different overlap welding strategies using green laser radiation for dissimilar metal welding. A microstructural analysis of the different fusion zones and mechanical strength of the joints are presented. In addition, the experimental parameter sets were analyzed regarding their application in battery module busbars by examining the electrical resistance and temperature distribution after welding. A parameter window was identified for all investigated welding strategies, with the stitched seam achieving the most stable results.

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Section: Resultssupporting

confidence: 90%

Section: State Of the Artmentioning

confidence: 99%

Section: State Of the Artmentioning

confidence: 99%

Section: State Of the Artmentioning

confidence: 99%

See 2 more Smart Citations

Seam Properties of Overlap Welding Strategies from Copper to Aluminum Using Green Laser Radiation for Battery Tab Connections in Electric Vehicles

et al. 2023

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“…Fig 28. Cross-sectional view of Cu-Al joint with schematic and micrograph showing the failure location after tensile shear test49) …”

mentioning

confidence: 99%

Study on Laser Welding of Dissimilar Materials between Aluminum and Copper (Ⅰ) - Research Trend in Laser Welding Technology and Materials Testing Methods -

Kim¹,

Jeong²,

Yun³

et al. 2022

J Weld Join

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In the rapidly changing automobile market, the important issues in assembling electric vehicles (EVs) can be summarized as weight reduction and battery safety. For the battery manufacturing technology, welding of dissimilar materials is crucial to assure the functionality and reliability of the battery systems installed in the recently developed EVs. This paper discusses research trends in laser welding technology for joining Al and Cu, which is currently applied for the joining process in the battery pack manufacturing. Laser welding of Al/Cu is well known to be very difficult owing to the formation of brittle intermetallic compounds as well as the low absorption rate of laser beam in both Al and Cu. Thus, the energy absorption rate, optimal energy density (beam size), welding heat input, beam modulation, and laser wavelength should be carefully optimized. The quality of dissimilar Al/Cu laser welding has been assessed by evaluating tensile and electrical properties. However, no standardized testing method exists for the laser welded materials. Therefore, standards must be urgently established for the mechanical and electrical evaluation of the laser welded materials. From the tear-down analysis of commercially produced battery modules in domestic EV, the quality of Al/Cu and Cu/Cu laser welds is critically assessed. For future research, the monitoring technology for reliable real-time laser welding should be developed for the mass-production of EV battery systems with better productivity and higher reliability.

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A study on the mechanical and electrical performance of Al/Cu laser multi-seam welded joints

Yoon,

Eun,

Bang

2024

Int J Adv Manuf Technol

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Aluminum alloy and copper used in lithium-ion batteries have low absorption and high reflectivity, so it is difficult to obtain stable joint strength when laser welding is applied. In order to overcome problems, this study has applied multi-seam weld to increase joint area of welded joints. An AA1050-H18 and C11020P sheets with a thickness of 0.5 mm were welded by 2 kW fiber laser welding. Effect of the welding parameters of pitch (0, 1, 4, 8 mm) on weldability in welded joints has been investigated. As the pitch of multi-seam increased, the tensile-shear load tended to increase. The maximum tensile-shear load in the multi-seam weld of pitch 8 mm was 1.25 kN, which was about 108% compared to the single-weld seam 0.6 kN. In addition, the minimum electrical resistance was 77 μΩ at the pitch of 8 mm, which decreased by approximately 49% compared to 115 μΩ of single seam welding. It is thought because resistance reduction caused by be changed from serial to parallel in multi-seam welding.

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

Cited by 4 publications

References 13 publications

Seam Properties of Overlap Welding Strategies from Copper to Aluminum Using Green Laser Radiation for Battery Tab Connections in Electric Vehicles

Seam Properties of Overlap Welding Strategies from Copper to Aluminum Using Green Laser Radiation for Battery Tab Connections in Electric Vehicles

Study on Laser Welding of Dissimilar Materials between Aluminum and Copper (Ⅰ) - Research Trend in Laser Welding Technology and Materials Testing Methods -

A study on the mechanical and electrical performance of Al/Cu laser multi-seam welded joints

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