研究目的
Investigating the overlap joining of aluminium and copper using laser micro welding with spatial power modulation for high power battery systems in electric mobility.
研究成果
The study demonstrates that spatial power modulation can adjust the weld seam geometry and influence the mixing behaviour of aluminium and copper. The configuration with aluminium as the top layer shows more reproducible results and less intermetallic phase formation in the transition area. Future investigations could explore different oscillation frequencies or shapes to further optimize the welding process.
研究不足
The process window for welding copper as a top layer is smaller and more sensitive to parameter changes. The formation of intermetallic phases and pores can affect the mechanical and electrical properties of the weld seam.
1：Experimental Design and Method Selection:
The study uses a laser beam welding process with spatial power modulation to investigate overlap joints of copper and aluminium. The influence of laser power, feed rate, and spatial power modulation on weld seam geometry and mixing behaviour is examined.
2：Sample Selection and Data Sources:
Aluminium Al 99.5 and copper Cu-ETP sheets of 0.5 mm thickness are used due to their wide distribution, availability, and purity.
3：5 and copper Cu-ETP sheets of 5 mm thickness are used due to their wide distribution, availability, and purity.
List of Experimental Equipment and Materials:
3. List of Experimental Equipment and Materials: A single-mode fibre laser (IPG Laser YLS1000SM) with a maximum power of 1000 W and a wavelength of 1070 nm, f-theta optics with a focal length of 163 mm, and a galvanometric scanner for spatial power modulation.
4：Experimental Procedures and Operational Workflow:
The welding zone is flooded with argon as shielding gas. Probes are cleaned with ethanol before welding. Weld seams have a length of 10 mm. Experiments are conducted with aluminium on top of the copper sheet and vice versa.
5：Data Analysis Methods:
Metallographic analysis, energy-dispersive X-ray spectroscopy (EDX) for intermetallic mixing, and tensile tests for mechanical properties.
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