Laser Welding Al to Al-Metallographic Analysis

00-Key parameters of laser beam welding for aluminum

Ø Laser power: Suggest to use a higher power setting, typically ranging from 1500W to 3000W. The selection of power should be determined based on the thickness of the aluminum plate. The thicker the plate, the higher the required power

Ø Welding speed: The recommended welding speed range is 20mm/s to 100mm/s. The selection of speed also needs to be adjusted according to the thickness of the plate to ensure welding quality and efficiency

Ø Welding depth and Welding width: Welding depth is between 0.5-5mm, and welding width is between 0.5-3mm. The setting of these parameters will directly affect the strength and appearance of the weld seam

Ø Focal length adjustment: The focal length adjustment range is usually between -2mm and+2mm, adjusted appropriately according to the thickness of the material to ensure accurate focusing of the laser beam

01-Principles of Laser Welding Technology

Ø Use high-energy density laser beams to heat the welding area

Ø The laser beam can focus on a very small area, causing the temperature of the local area to rapidly rise to the temperature of melting copper/alminium material, which cause it to melt and mix. After cooling, it forms a solid welding structure.

Ø The evaluation elements for welding quality include the appearance of the welding point, weld seam density, porosity, cracks and other defects

02-Advantages of laser welding copper busbar

Ø Laser welding is an efficient and high-precision welding method. Compared to traditional gas welding and arc welding, laser welding has the following advantages

Ø High speed: Laser welding has a fast speed, which can significantly shorten welding time and improve production efficiency

Ø High precision: Laser welding has high weld seam precision, which can achieve welding of small parts and improve the accuracy and quality

Ø No additional welding materials required: Laser welding does not require additional welding materials, avoiding pollution and waste

Ø Small heat affected zone, low deformation, and no joints

Ø Wide applicability: Laser welding is suitable for welding various materials, Which include copper busbars, aluminum busbars, stainless steel, etc

03-Precautions for laser welding copper busbars

Ø Copper has good thermal conductivity, but its coefficient of thermal expansion is relatively high, and welding parameters need to be adjusted according to specific situations

Ø Copper is prone to oxidation, so it is necessary to keep the welding area clean and dry during the welding process

Ø When the thickness of the copper busbar is big, it is necessary to use multi pass welding to ensure the welding quality

Ø For copper busbars that require high precision, high-precision laser welding equipment and technology need to be used