CoChat
Sign Up
Cited by 11Welding Techniques and Residual StressesAdvanced Welding Techniques AnalysisAdditive Manufacturing Materials and Processes

Study on Laser Welding of Dissimilar Materials between Aluminum and Copper (Ⅰ) - Research Trend in Laser Welding Technology and Materials Testing Methods -

Open access
Kim, Yong, Jeong, Su Jin, Yun, Seong Min, Lee, Je In·2022·Journal of Welding and Joining
DOI 10.5781/jwj.2022.40.5.7
Open this paper in CoChat — free accountOpen PDF

Abstract

In the rapidly changing automobile market, the important issues in assembling electric vehicles (EVs) can be summarized as weight reduction and battery safety. For the battery manufacturing technology, welding of dissimilar materials is crucial to assure the functionality and reliability of the battery systems installed in the recently developed EVs. This paper discusses research trends in laser welding technology for joining Al and Cu, which is currently applied for the joining process in the battery pack manufacturing. Laser welding of Al/Cu is well known to be very difficult owing to the formation of brittle intermetallic compounds as well as the low absorption rate of laser beam in both Al and Cu. Thus, the energy absorption rate, optimal energy density (beam size), welding heat input, beam modulation, and laser wavelength should be carefully optimized. The quality of dissimilar Al/Cu laser welding has been assessed by evaluating tensile and electrical properties. However, no standardized testing method exists for the laser welded materials. Therefore, standards must be urgently established for the mechanical and electrical evaluation of the laser welded materials. From the tear-down analysis of commercially produced battery modules in domestic EV, the quality of Al/Cu and Cu/Cu laser welds is critically assessed. For future research, the monitoring technology for reliable real-time laser welding should be developed for the mass-production of EV battery systems with better productivity and higher reliability.

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.

A few free checks a day · papers already verified open instantly · results are public

Integrity signals

Registry

Crossref · 10.5781/jwj.2022.40.5.7

Cites

1 of 1 references verified0 citation errors · 0 not checkable

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.

A few free checks a day · papers already verified open instantly · results are public

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?

  • Significant mismatch in thermophysical and metallurgical properties (melting point, thermal conductivity, strength) makes joining Al and Cu difficult.

    “Despite their advantages, the significant mismatch in their thermophysical and metallurgical properties, such as melting point, thermal conductivity, and strength, makes joining difficult [3], [4].”

    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 [3]

    The paper says Al/Cu dissimilar welding is more difficult than welding a single material because brittle intermetallic compounds must be controlled (discussion preceding §3, page not shown). It also notes differing thermal-expansion coefficients (§4.2, p. 433). Our copy does not identify mismatches in melting point, thermal conductivity, or the base metals’ strength as the reasons joining is difficult. (LLM, conf=0.84)

    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

Flagged first, then by citations

Research works printed but not linked: 49

  1. H. Saariluoma, A. Piiroinen, A. Unt, J. Hakanen, T. Rautava, and A. Salminen, Overview of optical digital measuring challenges and technologies in laser welded components in EV battery module design and manu- facturing, Batteries. 6(3) (2020) 47. https://doi.org/10.3390/batteries6030047 · DOI · Paper page
  2. A. Das, D. Li, D. Williams, and D. Greenwood, Joining Technologies for Automotive Battery Systems Manu- facturing, World Electrc. Veh. J. 9(2) (2018) 22. https://doi.org/10.3390/wevj9020022 · DOI
  3. M. Kang, W. S. Choi, and S. Kang, Ultrasonic and laser welding technologies on Al/Cu dissimilar materials for the lithium-ion battery cell or module manufacturing, J. Weld. Join. 37(2) (2019) 52-59. https://doi.org/10.5781/JWJ.2019.37.2.8 · DOI
  4. Y. Kim and C. Kim, Recent trends about modulation technology of the laser beam welding, J. Weld. Join. 36(4) (2018) 47-57. https://doi.org/10.5781/JWJ.2018.36.4.5 · DOI
  5. J. Helm, A. Schulz, A. Olowinsky, A. Dohm, and R. Poprawe, Laser welding of laser-structured copper con- nectors for battery applications and power electronic, Weld. World. 64 (2020) 611-622. https://doi.org/10.1007/s40194-020-00849-8 · DOI
  6. S. Fujinaga, H. Takenaka, T. Narikiyo, S. Katayama, and A. Matsunawa, Direct observation of keyhole be- haviour during pulse modulated high power Nd:YAG laser irradiation, J. Phys. D: Appl. Phys. 33(5) (2000) 492-497. https://doi.org/10.1088/0022-3727/33/5/304 · DOI
  7. S. Grünenwald, V. Kujanpää, and A. Salminen, Nd: YAG laser welding of 5083 aluminum alloy using filler wire, Proceeding of ICALEO'07 1002 (2007). https://doi.org/10.2351/1.5060979 · DOI
  8. J. Yang, L. Chen, S. Gong, and X. Li, Study on the sur- face treatment for controlling the aluminum-lithium al- loy weld porosity of laser welding, PICALO'08, (2008) 499. https://doi.org/10.2351/1.5057065 · DOI
  9. Vyskoč. M, Sahul. M., and Sahul. M, Effect of shield- ing gas on the properties of AW 5083 aluminum alloy laser weld joints. J. Mater. Eng. Perform. 27 (2018) 2993-3006. https://doi.org/10.1007/s11665-018-3383-x · DOI
  10. C. Kim, M. Kang, and N. Kang, Solidification crack and morphology for laser weave welding of Al 5J32 alloy, Sci. Technol. Weld. Join. 18(1) 57-61. https://doi.org/10.1179/1362171812y.0000000073 · DOI
  11. L. Wang, M. Gao, C. Zhang, and X. Zeng, Effect of beam oscillating pattern on weld characterization of la- ser welding of AA6061-T6 aluminum alloy, Mater. Des. 108 (2016) 707-717. https://doi.org/10.1016/j.matdes.2016.07.053 · DOI
  12. S. Li, G. Mi, and C. Wang, A study on laser beam os- cillating welding characteristics for the 5083 alumi- num alloy: Morphology, microstructure and mechan- ical properties, J. Manuf. Process. 53 (2020) 12-20. https://doi.org/10.1016/j.jmapro.2020.01.018 · DOI
  13. J. P. Bergmann, M. Bielenin, M. Stambke, T. Feustel, P. Witzendorff, and J. Hermsdorf, Effect of diode laser superposition on pulsed laser welding of aluminum, Phys. Proc. 41 (2013) 180-189. https://doi.org/10.1016/j.phpro.2013.03.068 · DOI
  14. M. R. Maina, Y. Okamoto, A. Okada, M. Närhi, J. Kangastupa, and J. Vihinen, High surface quality welding of aluminum using adjustable ring-mode fiber laser, J. Mater. Process. Technol. 258 (2018) 180-188. https://doi.org/10.1016/j.jmatprotec.2018.03.030 · DOI
  15. T. Sun, P. Franciosa, M. Sokolov, and D. Ceglarek, Challenges and opportunities in laser welding of 6xxx high strength aluminum extrusions in automotive bat- tery tray construction, Procedia CIRP 94 (2020) 565-570. https://doi.org/10.1016/j.procir.2020.09.076 · DOI
  16. A. Heider, R. Weber, D. Herrmann, P. Herzog, and T. Graf, Power modulation to stabilize laser welding of copper, J. Laser Appl. 27(2) (2015) 1-8. https://doi.org/10.2351/1.4906127 · DOI
  17. S. Liebl, R. Wiedenmann, A. Ganser, P. Schmitx, and M.F. Zaeh, Laser welding of copper using multi mode fiber lasers at near infrared wavelength, Phys. Proc. 56 (2014) 591-600. https://doi.org/10.1016/j.phpro.2014.08.047 · DOI
  18. M. Weigl and M. Schmidt, Influence of the feed rate and the lateral beam displacement on the joining qual- ity of laser-welded copper stainless steel connections, Phys. Proc. 5 (2010) 53-59. https://doi.org/10.1016/j.phpro.2010.08.029 · DOI
  19. A. Moalem, P. von Witzendorff, U. Stute, and L. Overmeyer, Reliable copper spot welding with IR la- ser radiation through short prepulsing, Procedia CIRP 3 (2012) 459-464. https://doi.org/10.1016/j.procir.2012.07.079 · DOI
  20. S. I. Nakashiba, Y. Okamoto, T. Sakagawa, S. Takai, and A. Okada, Micro-welding of copper plate by fre- quency doubled diode pumped pulsed Nd:YAG Laser, Phys. Proc. 39 (2012) 577-584. https://doi.org/10.1016/j.phpro.2012.10.076 · DOI
  21. W.S. Chung, A. Olowinsky, and A. Gillner, Process studies on copper laser beam welding over gap by us- ing disc laser at green wavelength, J. Adv. Join. Process. 1 (2020). https://doi.org/10.1016/j.jajp.2020.100009 · DOI
  22. M. Haubold, A. Ganser, T. Eder, and M. F. Zäh, Laser welding of copper using a high power disc laser at green wavelength, Procedia CIRP 74 (2018) 446-449. https://doi.org/10.1016/j.procir.2018.08.161 · DOI
  23. G. J Shannon, Laser welding of aluminum and copper for battery welding applications using a 500W single mode fiber laser, ICALEO'09 (2009) 1015-1020. https://doi.org/10.2351/1.5061446 · DOI
  24. A. Haeusler and A. Schurmann, Quality improvement of copper welds by laser microwelding with the usage of spatial power modulation, J. Laser Appl. 29(2) (2017). https://doi.org/10.2351/1.4983505 · DOI
  25. E. Punzel, F. Hugger, R. Dorringer, T. L. Dinkelbach, and A. Burger, Comparison of different system tech- nologies for continuous-wave laser beam welding of copper, Procedia CIRP 94 (2020) 587-591. https://doi.org/10.1016/j.procir.2020.09.081 · DOI
  26. G. Eber, I. Mys, and M. Schmidt, Laser micro welding of copper and aluminum using filler materials, Pro- ceeding of SPIE 5662 (2004). https://doi.org/10.1117/12.596330 · DOI
  27. I. Mys and M. Schmidt, Laser micro welding of copper and aluminum, Proceeding of SPIE 6107 (2006). https://doi.org/10.1117/12.648376 · DOI
  28. M. Weigl, F. Albert, and M. Schmidt, Enhancing the ductility of laser welded copper aluminum con- nections by using adapted filler materials, Phys. Proc. 12 (2011) 332-338. https://doi.org/10.1016/j.phpro.2011.03.141 · DOI
  29. T. Solchenbach, P. Plapper, and W. Cai, Electrical per- formance of laser braze-welded aluminum copper in- terconnects, J. Manuf. Proc. 16 (2014) 183-189. http://dx.doi.org/10.1016/j.jmapro.2013.12.002 · DOI
  30. P. Schmalen and P. Plapper, Evaluation of laser braze welded dissimilar Al-Cu joints, Phys. Proc. 83 (2016) 506-514. https://doi.org/10.1016/j.phpro.2016.08.052 · DOI
  31. K. Mathivanan and P. Plapper, Laser welding of dis- similar copper and aluminum sheets by shaping the laser pulses, Proc. Manuf. 36 (2019) 154-162. https://doi.org/10.1016/j.promfg.2019.08.021 · DOI
  32. P. Schmidt, M. Schweier, and M. Zaeh, Joining of lith- ium-ion batterys using laser beam welding: Electrical losses of welded aluminum and copper joints, ICALEO '12 (2012) 915-923. https://doi.org/10.2351/1.5062563 · DOI
  33. M. Hailat, A. Mian, Z. Chaudhury, G. Newaz, R. Patwa, and H. Herfurth, Laser micro welding of aluminum and copper with and without tin foil alloy, Microsyst Technol. 18 (2012) 103-112. https://doi.org/10.1007/s00542-011-1378-8 · DOI
  34. S. Lee, H. Nakamura, Y. Kawahito, and S. Katayama, Effect of welding speed on microstructural and me- chanical properties of laser lap weld joints in dissim- ilar Al and Cu sheets, Sci. Technol. Weld. Join. 19(2) (2014) 111-118. https://doi.org/10.1179/1362171813Y.0000000168 · DOI
  35. U. Reisgen, S. Olschok, S. Jakobs, and N. Holtum, Influence of the degree of dilution with laser beam vacuum-welded Cu-Al mixed joints on the electrical properties, Procedia CIRP 74 (2018) 23-26. https://doi.org/10.1016/j.procir.2018.08.022 · DOI
  36. U. Reisgen, S. Olschok, S. Jakobs, and C. Turner, Sound welding of copper: Laser beam welding in vac- uum, Phys. Proc. 83 (2016) 447-454. https://doi.org/10.1016/j.phpro.2016.08.046 · DOI
  37. A. Fortunato and A. Ascari, Laser welding of thin cop- per and aluminum sheets: Feasibility and challenges in continuous wave welding of dissimilar metals, Lasers Manuf. Mater. Process. 6(2) (2019) 136-157. https://doi.org/10.1007/s40516-019-00085-z · DOI
  38. S. Hollatz, P. Heinen, E. Limpert, A. Olowinsky, and A. Gillner, Overlap joining of aluminium and copper using laser micro welding with spatial power modu- lation, Weld. World 64 (2020) 513-522. https://doi.org/10.1007/s40194-020-00848-9 · DOI · Paper page
  39. M. Kang, T. Park, C. Kim, and J. Kim, Laser welding characteristics of aluminum and copper sheets for Lithium-ion batteries, J. Korean Weld. Join. Soc. 31(6) (2013) 58-64. http://dx.doi.org/10.5781/KWJS.2013.31.6.58 · DOI
  40. S. Yan and Y. Shi, Influence of laser power on micro- structure and mechanical property of laser welded Al/Cu dissimilar lap joints, J. Manuf. Process. 45 (2019) 312-321. https://doi.org/10.1016/j.jmapro.2019.07.009 · DOI
  41. S. Yan and Y. Shi, Influence of Ni interlayer on micro- structure and mechanical properties of laser welded joint of Al/Cu bimetal, J. Manuf. Process. 59 (2020) 343-354. https://doi.org/10.1016/j.jmapro.2020.09.078 · DOI
  42. K. Mathivanan and P. Plapper, Artificial neural net- work to predict the weld status in laser welding of copper to aluminum, Procedia CIRP 103 (2021) 61-66. https://doi.org/10.1016/j.procir.2021.10.009 · DOI
  43. M. R. Maina, Y. Okamoto, A. Okada, M. Närhi, J. Kangastupa, and J. Vihinen, High surface quality weld- ing of aluminum using adjustable ring-mode fiber la- ser, J. Mater. Process. Technol. 258 (2018) 180-188. https://doi.org/10.1016/j.jmatprotec.2018.03.030 · DOI
  44. J. Cha and H. Choi, Characterization of dissimilar alu- minum copper material joining by controlled dual la- ser beam, Int. J. Adv. Manuf. Technol. 119 (2022) 1909-1920. https://doi.org/10.1007/s00170-021-08324-4 · DOI
  45. V. Dimatteo, A. Ascari, E. Liverani, and A. Fortunato, Experimental investigation on the effect of spot diam- eter on continuous-wave laser welding of copper and aluminum thin sheets for battery manufacturing, Opt. Laser Technol. 145 (2022) 107495. https://doi.org/10.1016/j.optlastec.2021.107495 · DOI
  46. T. Kim and H. Choi, Study on laser welding of Al-Cu dissimilar material by green laser and weld quality evaluation by deep learning, J. Weld. Join. 39(1) (2021) 67-73. https://doi.org/10.5781/JWJ.2021.39.1.8 · DOI
  47. K. Mathivanan and P. Plapper, Welding of copper to aluminum with laser beam wavelength of 515 nm, Preprints, (2021). https://doi.org/10.20944/preprints202108.0443.v1 · DOI
  48. W. Lai, S. Sung, J. Pan, Y. Guo, and X. Su, Failure mode and fatigue behavior of dissimilar laser welds in lap shear specimens of aluminum and copper sheets, SAE Int. J. Mater. Manf. 7(3) (2014) 706-710. https://doi.org/10.4271/2014-01-1986 · DOI
  49. F. Fetzer, M. Jarwitz, P. Stritt, R. Weber, and T. Graf, Fine-tuned remote laser welding of aluminum to cop- per with local beam oscillation, Phys. Proc. 83 (2016) 455-462. https://doi.org/10.1016/j.phpro.2016.08.047 · DOI

Cited by

Sorted by citations

Authors
Kim, Y., Jeong, S. J., Yun, S. M., & Lee, J. I.
Affiliations
Institute for Advanced Engineering (KR)
Corresponding author
Lee, Je In
ORCID
Venue
Journal of Welding and Joining
Publisher
The Korean Welding and Joining Society
Published
2022-10-31
Volume
40
Issue
5
Pages
416-437
ISSN
  • 1225-6153 (ISSN-L)
  • 2466-2232
  • 2466-2100
DOI
10.5781/jwj.2022.40.5.7
OpenAlex
W4297463981
Cited by
11
References
1
Citations by year
2026: 3 · 2025: 3 · 2024: 4 · 2023: 1
FWCI
0.75
Type
journal article
Language
en
Open access
Licence
Locations
Journal of Welding and Joining (publishedVersion, cc-by-nc-nd)
Funders
Ministry of Trade, Industry and Energy (20017418)
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
laser welding, dissimilar metal joining, aluminum-copper joining, electric vehicle batteries, intermetallic compounds, energy density, beam modulation, laser wavelength, tensile properties, electrical conductivity, weld quality assessment, mass production

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