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Successful joining of aluminum and copper was carried out by the application of continuous laser beam. While lap welding 99.60% pure aluminum (Al) 1060 alloy and pure copper (Cu) UNS C10100, which is oxygen free, a single-mode continuous wave (CW) Yb: fiber laser operating at 1080 nm wavelength produced a 100 µm spot size. The success of the joints was mostly confirmed by the weld mechanical and microstructural properties as investigated under SEM and vicker’s hardness test. The various combinations of weld parameters generated various modes of welds such as the conduction mode, keyhole mode, and mixed mode of conduction and keyhole mode. These modes variation could also be easily correlated with the variation of the input volume energy. The keyhole mode exhibited higher weld strength due to formation of adequate IMCs, good contact area and high penetration depth. In contrast, the conduction mode welds represented poor mechanical properties due to very low contact area, penetration depth, and IMC formation.

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Laser Lap Welding of Aluminum and Copper Used for Manufacturing Lithium-Ion Batteries: Microstructural and Mechanical Property Correlation

  • 会议论文

  • 发表日期：

    2025年

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  • Mounarik Mondal,
  • Adhirath Mandal,
  • Pratiksha Mandrekar

摘要

Successful joining of aluminum and copper was carried out by the application of continuous laser beam. While lap welding 99.60% pure aluminum (Al) 1060 alloy and pure copper (Cu) UNS C10100, which is oxygen free, a single-mode continuous wave (CW) Yb: fiber laser operating at 1080 nm wavelength produced a 100 µm spot size. The success of the joints was mostly confirmed by the weld mechanical and microstructural properties as investigated under SEM and vicker’s hardness test. The various combinations of weld parameters generated various modes of welds such as the conduction mode, keyhole mode, and mixed mode of conduction and keyhole mode. These modes variation could also be easily correlated with the variation of the input volume energy. The keyhole mode exhibited higher weld strength due to formation of adequate IMCs, good contact area and high penetration depth. In contrast, the conduction mode welds represented poor mechanical properties due to very low contact area, penetration depth, and IMC formation.