Overlap joining of aluminium and copper using laser micro welding with spatial power modulation
Open accessAbstract
The rising demand for high power battery systems for the electric mobility requires the connection of a large number of cells. Due to the functionality of the cell chemistry, a combination of copper and aluminium is necessary. The differing material properties like thermal conductivity as well as the formation of intermetallic phases are challenging for welding processes. This study contains the results for overlap joints of copper and aluminium using a laser beam welding process with spatial power modulation. With a parameter variation, the cross-sectional shape of the weld seams and therefore, the ratio of depth to width can be adjusted. With additional longitudinal cross sections and an energy-dispersive X-ray spectroscopy analysis, the different mixing behaviour of the dissimilar material depending on the top layer is investigated.
The claims and statistics of this paper haven’t been checked yet.
Run the check — free, no account needed. It reads the open-access text and checks the sources it cites.
Integrity signals
Registry
Cites
Statistics
Claims the paper makes
The claims and statistics of this paper haven’t been checked yet.
Run the check — free, no account needed. It reads the open-access text and checks the sources it cites.
Claims other papers make about this one
Each is checked against this paper’s own text: does it say what the citing paper says it does?
Insufficient heat input can result in incomplete or weak bonding, while excessive heat input may degrade joint strength by promoting thermal instability.
“Insufficient heat input can result in incomplete or weak bonding, while excessive heat input may degrade joint strength by promoting thermal instability [39].”
From Effect of nickel interlayer thickness on intermetallic compound formation and interfacial integrity in pulsed laser welding of aluminum and copper (2026) · cites this paper as [39]
Section 4.2.1 (page not provided) reports that laser power outside the usable range produced either no connection or full penetration of the lower joining material. This supports the insufficient-input part and shows a problem at excessive power, but it does not establish that excessive heat input reduced joint strength by promoting thermal instability. (LLM, conf=0.85)
Experimental — accuracy not yet measuredExcessive heat retention can adversely affect weld integrity.
“However, such excessive heat retention can adversely affect weld integrity [39].”
From Effect of nickel interlayer thickness on intermetallic compound formation and interfacial integrity in pulsed laser welding of aluminum and copper (2026) · cites this paper as [39]
Section 4.2.4 says that less time for heat to dissipate concentrates heat in the weld, producing deeper seams and more material mixing. Section 2.2 says intermetallic phases formed in aluminium–copper welds can make joints brittle and prone to cracking. The paper does not directly establish that excessive heat retention itself damages weld integrity. (LLM, conf=0.76)
Experimental — accuracy not yet measured
Self-check
Percentages, sums and reported differences re-computed from the paper’s own numbers.
The self-check needs the paper’s full text.
Cites
No references could be resolved yet.
Research works printed but not linked: 7
- Kothauer R (2013) Handbuch Lithium-Ionen-Batterien. Springer, Berlin
- Brand M, Schmidt P, Zaeh M, Jossen A (2015) Welding techniques for battery cells and resulting electrical contact resistances. Journal of Energy Storage 1:7-14
- Poprawe R (2011) Tailored light 2. Springer, Berlin, Heidelberg
- Haeusler A, Schuermann A, Schoeler C et al (2017) Quality im- provement of copper welds by laser microwelding with the usage of spatial power modulation. Journal of Laser Applications 29
- Schmitt F (2012) Laserstrahl-Mikroschweißen mit Strahlquellen hoher Brillanz und örtlicher Leis-tungsmodulation. Dissertation, RWTH Aachen, Shaker, Aachen Germany
- Choi S et al (2012) Vibration analysis in robotic ultrasonic welding for battery assembly. IEEE International Conference on Technologies for Practical Robot Applications (TePRA)
- Hess A (2012) Vorteile und Herausforderungen beim Laserstrahlschweißen mit Strahlquellen höchster Fokussierbarkeit. University of Stuttgart, Herbert Utz Verlag, Dissertation
Cited by
Sorted by citations
Kumar, A., Neogy, S., Saini, S., Ittoop, M. O., Chowdhury, A., Sajith, B. K., & Ganesh, P. (2025) · Welding International · doi:10.1080/09507116.2024.2432396 · Cited by 7 · see citing works
Singh, R., Arora, N., & Choudhary, A. (2026) · Welding in the World · doi:10.1007/s40194-026-02375-5 · Cited by 6 · see citing works
“The strong quenching effect from Cu also limited weld bead widening, consistent with observations by Hollatz et al. [39].”
- Authors
- Hollatz, S., Heinen, P., Limpert, E., Olowinsky, A., & Gillner, A.
- Affiliations
- Fraunhofer Institute for Laser Technology (DE)
- RWTH Aachen University (DE)
- Corresponding author
- Hollatz, S.
- Venue
- Welding in the World
- Published
- 2020-01-28
- Volume
- 64
- Issue
- 3
- Pages
- 513-522
- ISSN
- 0043-2288 (ISSN-L)
- 1878-6669
- OpenAlex
- W3003546864
- Cited by
- 38
- References
- 0
- Citations by year
- 2026: 7 · 2025: 3 · 2024: 12 · 2023: 5 · 2022: 3 · 2021: 7 · 2020: 1
- FWCI
- 1.97
- Type
- journal article
- Language
- en
- Open access
- hybrid
- doi.org
- Locations
- Welding in the World (publishedVersion, cc-by)
- Publikationsdatenbank der Fraunhofer-Gesellschaft (Fraunhofer-Gesellschaft) (submittedVersion, other-oa)
- Fraunhofer-Publica (Fraunhofer-Gesellschaft) (submittedVersion)
- RWTH Publications (RWTH Aachen) (submittedVersion, other-oa)
- Funders
- Fraunhofer Institute for Laser Technology (ILT)
- Topics
- Physical Sciences › Engineering › Mechanical Engineering › Welding Techniques and Residual Stresses
- Physical Sciences › Engineering › Mechanical Engineering › Advanced Welding Techniques Analysis
- Physical Sciences › Engineering › Mechanical Engineering › Additive Manufacturing Materials and Processes
- Keywords
- aluminum-copper dissimilar joining, laser micro-welding, lap joints, intermetallic compounds, depth-to-width ratio, electric vehicle batteries
About these checks
Registry, retraction, Cites and statistics results are computed, not judged, with one exception: a printed reference that no index lists is read once by a model before it counts as a citation error. Claims are extracted by a model and kept only when their quote appears verbatim in the text; each cited source is then checked, with a model’s help, for whether it says what the claim relies on. Those verdicts can be wrong — read the claim’s quote and the cited source before relying on one.
Statistics and arithmetic are recomputed, not judged.
Confidence bands are shown only for fields calibrated on our annotated test set. None is calibrated yet, so no band is shown.
What counts as a claim ›How we measure confidence ›How we check this ›
Are you an author, or do you see a problem with this page? Request a review
