Towards an Understanding of the Challenges in Laser Beam Welding of Copper – Observation of the Laser-Matter Interaction Zone in Laser Beam Welding of Copper and Steel Using in Situ Synchrotron X-Ray Imaging

Abstract The increasing demand for contacting applications in electric components such as batteries, power electronics and electric drives is boosting the use of laser-based copper processing. Laser beam welding is a key for an efficient and high-quality electric vehicle production due to its local, non-contact energy input and high automation capability enabling reproducible weld quality. Nevertheless, a major challenge in process design is the combination of energy-efficiency and precise process guidance with regard to weld seam depth and defect prevention (i.e. spatter, melt ejections), partly caused by the high thermal conductivity of copper. High power lasers in the near infrared range and emerging visible laser beam sources with excellent beam quality can provide a suitable joining solution for this purpose. However, the underlying physical phenomena are currently only partly understood and a reflection on the challenges of laser beam welding of copper compared to well researched steel processing has not yet been carried out. In order to improve the understanding of the effect of the different material properties and the influence of process parameters on the vapor capillary and melt pool geometry in laser beam welding, in situ synchrotron investigations on Cu-ETP and S235 using 515 and 1030 nm laser sources were conducted. The material phase contrast analysis was successfully used to distinguish vapor capillary and melt pool phase boundaries during the welding process with high spatial and temporal resolution up to 5 kHz. A significantly different vapor capillary geometry and sensitivity to parameter variation were found between the steel and copper material. In addition, the visualization of characteristic melt flows revealed different melt pool dynamics and a pronounced eddy close to the melt pool surface for copper, which is assumed to be causal for the observation of pronounced spatter formation during copper welding in a certain process window.