A Study on the Green Laser Weldability of Copper-aluminum Battery Materials

Copper is widely utilized in electric vehicle batteries due to its excellent electrical conductivity, lightweight, and excellent corrosion resistance. However, copper has a high reflectivity of about 97% for infrared lasers, which makes it difficult to achieve stable welding quality. This study investigated using a green laser to weld nickel-coated copper and aluminum materials. After performing welding by changing the laser power and scan speed, the weld cross-section was observed with an optical microscope, and it was confirmed that the welding penetration depth and bead width increased as the heat input increased. The spatter on the bead surface and defects such as pores and cracks in the weld were caused by excessive heat input. Analysis of the weld cross-section using SEM-EDS showed that high heat input increased the formation of intermetallic compounds including CuAl2 and Cu9Al4. The mechanical properties of the weld were examined using a shear tensile test. The analysis results showed that intermetallic compounds caused brittleness in the weld joint, which lowered mechanical properties and caused defects such as pores and cracks. P60 (1.2 kW, scan speed: 250 mm/s), P80 (1.6 kW, scan speed: 375 mm/s), and P100 (1.2 kW, scan speed: 375 mm/s) were examples of excellent mechanical quality. The fastest welding condition, P100 (power: 2 kW, scan speed: 450 mm/s), was suggested as the most efficient welding condition.