A study on cracks and IMCs in laser welding of Al and Cu

Kyubok Lee; Teresa J. Rinker; Masoud M. Pour; Wayne Cai; Wenkang Huang; Wenda Tan; Jennifer Bracey; Jingjing Li

doi:10.1016/j.mfglet.2023.08.026

A study on cracks and IMCs in laser welding of Al and Cu

Kyubok Lee, Teresa J. Rinker, Masoud M. Pour, Wayne Cai, Wenkang Huang, Wenda Tan, Jennifer Bracey, Jingjing Li

Marcus Department of Industrial and Manufacturing Engineering

Research output: Contribution to journal › Article › peer-review

3 Scopus citations

Abstract

Aluminum-copper laser welding has become a crucial joining technology for battery manufacturing. However, dissimilar material mixing in welding often causes the formation of intermetallic compounds (IMCs) and cracks, which reduce weld quality. In this study, the effects of laser power and welding speed on material mixing, IMCs formations, and crack formation were investigated by 3D micro-X-ray computed tomography imaging, computational fluid dynamics, and chemical/elemental analyses. Of crack formation during Al-Cu laser welding, transverse cracking was found to be the major type. The crack formation is associated with the IMC distributions generated throughout the weld fusion zone when high laser energy input caused more extensive Al/Cu material mixing.

Original language	English (US)
Pages (from-to)	221-231
Number of pages	11
Journal	Manufacturing Letters
Volume	35
DOIs	https://doi.org/10.1016/j.mfglet.2023.08.026
State	Published - Aug 2023

All Science Journal Classification (ASJC) codes

Mechanics of Materials
Industrial and Manufacturing Engineering

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10.1016/j.mfglet.2023.08.026

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title = "A study on cracks and IMCs in laser welding of Al and Cu",

abstract = "Aluminum-copper laser welding has become a crucial joining technology for battery manufacturing. However, dissimilar material mixing in welding often causes the formation of intermetallic compounds (IMCs) and cracks, which reduce weld quality. In this study, the effects of laser power and welding speed on material mixing, IMCs formations, and crack formation were investigated by 3D micro-X-ray computed tomography imaging, computational fluid dynamics, and chemical/elemental analyses. Of crack formation during Al-Cu laser welding, transverse cracking was found to be the major type. The crack formation is associated with the IMC distributions generated throughout the weld fusion zone when high laser energy input caused more extensive Al/Cu material mixing.",

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T1 - A study on cracks and IMCs in laser welding of Al and Cu

AU - Lee, Kyubok

AU - Rinker, Teresa J.

AU - Pour, Masoud M.

AU - Cai, Wayne

AU - Huang, Wenkang

AU - Tan, Wenda

AU - Bracey, Jennifer

AU - Li, Jingjing

PY - 2023/8

Y1 - 2023/8

N2 - Aluminum-copper laser welding has become a crucial joining technology for battery manufacturing. However, dissimilar material mixing in welding often causes the formation of intermetallic compounds (IMCs) and cracks, which reduce weld quality. In this study, the effects of laser power and welding speed on material mixing, IMCs formations, and crack formation were investigated by 3D micro-X-ray computed tomography imaging, computational fluid dynamics, and chemical/elemental analyses. Of crack formation during Al-Cu laser welding, transverse cracking was found to be the major type. The crack formation is associated with the IMC distributions generated throughout the weld fusion zone when high laser energy input caused more extensive Al/Cu material mixing.

AB - Aluminum-copper laser welding has become a crucial joining technology for battery manufacturing. However, dissimilar material mixing in welding often causes the formation of intermetallic compounds (IMCs) and cracks, which reduce weld quality. In this study, the effects of laser power and welding speed on material mixing, IMCs formations, and crack formation were investigated by 3D micro-X-ray computed tomography imaging, computational fluid dynamics, and chemical/elemental analyses. Of crack formation during Al-Cu laser welding, transverse cracking was found to be the major type. The crack formation is associated with the IMC distributions generated throughout the weld fusion zone when high laser energy input caused more extensive Al/Cu material mixing.

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JO - Manufacturing Letters

JF - Manufacturing Letters

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A study on cracks and IMCs in laser welding of Al and Cu

Abstract

All Science Journal Classification (ASJC) codes

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