Product Code: ICA10_1603

Laser Welding of Dissimilar Copper-Aluminum Connections by Means of Roll-Cladded Inserts
Authors:
Markus Weigl, Bayerisches Laserzentrum GmbH; Erlangen Germany
Alexander Grimm, Bayerisches Laserzentrum GmbH; Erlangen Germany
Thomas Frick, Bayerisches Laserzentrum GmbH; Erlangen Germany
Michael Schmidt, Chair of Photonic Technologies, University of Erlangen-Nuernberg; Erlangen Germany
Presented at ICALEO 2010

Thermal welding processes of copper and aluminum often lead to insufficient connections due to an embrittlement and an unsatisfactory ductility of the melting zone. This embrittlement is caused by an extensive intermixture of the dissimilar base materials during the molten state which effectuates a formation of intermetallic phases. While it is possible to increase the tensile strength of copper-aluminum joints using micro alloying methods and a lateral beam displacement, the ductility of such connections is still limited to a certain extent.
A promising approach to reach a higher ductility of dissimilar copper-aluminum connections is the use of roll-cladded copper-aluminum sheet metal for the laser-welding process. With the standardized roll-cladding technique it is possible to reach excellent copper-aluminum connections by cold-pressure welding. Such roll-cladded elements can be used to split the joining sequence of copper and aluminum into two separate joining steps, which is on the one side an aluminum-aluminum welding and on the other side a copper-copper welding.
Indeed the most important challenge for the guiding of the joining process is the prevention of intermetallic phases within the roll-cladded inserts, as the thermal laser-welding influences the contact layer of copper and aluminum inside the roll-cladded sheet metal.

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