Laser Welding Cu to Cu-Metallographic Analysis

00-The key parameters of the laser welding copper

Ø Laser power: 1000W to 4000W, adjusted according to the thickness of the copper material and welding speed

Ø Welding speed: for example, 0.3m/min to 2.5m/min, it needs to be matched with the laser power to ensure welding quality

Ø Spot size: 0.2mm to 1.2mm, select the appropriate spot size based on the width of the weld seam

Ø Welding focus length: for example, 150mm to 300mm, adjust the focus length to achieve the best welding effect

Ø Protective gas: such as argon, used to prevent oxidation of copper during welding process

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, Advantages as follow

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

04-Application of flexible copper busbar Laser Welding Technology

The rapid development of new energy vehicles has further promoted the application of flexible copper busbar Laser Welding Technology.In the connection of battery packs, flexible copper busbar are important conductive components, and their welding quality directly affects the performance and safety of the battery.Laser welding can reduce the thermal impact to batteries and lower the risk of overheating in battery packs while ensuring welding strength. The high efficiency of laser welding has increased the automation level of production lines, meeting the needs of large-scale production.

In practical applications, laser welding technology for flexible copper bars still faces some challenges. Firstly, the optimization of welding parameters. flexible copper bars of different thicknesses and shapes need to adjust parameters such as laser power, welding speed, and focal length according to specific situations,to ensure welding quality. During the welding process, porosity and sundries may occur, which will affect the performance of the weld seam. Before welding, the material needs to be treated to ensure surface cleanliness and reduce impurities.

The investment of laser welding equipment is relatively high, and the initial investment may cause certain economic pressure on small businesses. However, with the continuous advancement of technology and the reduction of equipment costs, the popularization of laser welding will become a trend.When enterprises adopt laser welding technology, they also need to strengthen employee training and improve operational skills to ensure the stability and reliability of the welding process.

In the future development, the laser welding technology of flexible copper bar is expected to be combined with intelligent manufacturing and industrial Internet to promote the further upgrading of welding technology. By collecting and analyzing data, the welding process can be monitored in real-time,Timely adjust welding parameters to improve welding quality and production efficiency. Combining advanced manufacturing technologies such as 3D printing, the design and production of flexible copper bars will be more flexible and meet personalized needs.

Overall, the application potential of flexible copper busbar laser welding technology in various fields is enormous. With the continuous advancement of technology and the growth of market demand, laser welding technology will undoubtedly have a significant impact on future electrical engineering,The fields of electronic manufacturing and new energy vehicles play a more important role. Through continuous exploration and innovation, we will have more efficient and environmentally friendly connection methods, Which will inject new vitality into the development of various industries