Laser Copper Welding with Blue High Power Diode Laser
445 nm wavelength and 4 kW laser power (CW) for laser welding of copper, gold and other non-ferrous metals.
To the examples
445 nm wavelength and 4 kW laser power (CW) for laser welding of copper, gold and other non-ferrous metals.
To the examplesThe blue laser enables controlled heat conduction welding of copper and other non-ferrous metals with low material thickness. Whereas thin foils were previously cut rather than joined with an infrared laser, the blue laser can now be used to process the material in a targeted and controlled manner. The blue laser beam is used to melt the desired material along the joints. The liquefied materials flow into each other and form the weld seam as they cool. This process produces particularly smooth seams that are of excellent quality and therefore highly stable. The process is basically the same as with an infrared laser - apart from the wavelength used.
With industrial laser beam sources available to date, it was only possible to process non-ferrous metals such as copper successfully in series production with increased effort. The development of blue laser diodes opens up new possibilities because copper and gold in particular absorb the blue light spectrum seven to twenty times better than infrared radiation (see graphic).
The blue high power diode laser significantly improves the laser material processing of non-ferrous metals. Thin foils and sheets, in particular, can be processed much more effectively with the blue laser, but the blue diode laser offers even more advantages, too.
In addition to the high absorption of blue light, which makes it much easier to melt copper, the use of the intensity profile characteristic of diode lasers also contributes to the top-notch processing outcome. Furthermore, Laserline’s proven diode laser technology allows the laser power to be finely graduated within milliseconds, thus adapting it perfectly to the process requirements. The weld seams created during copper welding are extremely clean and very smooth – regardless of the surface quality of the material before the welding process was begun. They have excellent electrical conductivity and produce little to no spatters on adjacent areas of the material. Material efficiency is also particularly high, as the blue laser, on the one hand, does not require any overlap or material reinforcement in the seam area, and on the other hand, liquid copper has a high gap bridgeability for processing with blue laser radiation. The option of controlled heat conduction welding enables copper to be used as the upper joining component when welding different metals, for the first time. Even copper powder and very thin copper foils can be joined to other materials, such as steel and aluminum. When it comes to welding foils, considerable results have already been achieved in butt and edge welding.
For users, the LDF and LDM platform provides a familiar and industrially proven system that can be used in conjunction with processing optics optimized for the wavelength. Otherwise, only a few modifications are needed to integrate the laser into production. The sight protection windows of processing cells and protective goggles are the only aspects that have to be replaced, due to the changed wavelength range, in order to meet laser safety requirements for the employees carrying out the work.
1 to 3 mm copper
0,8 to 1,5 mm copper
3 mm copper sheet
1 mm copper sheet
1,2 on 1,2 mm copper sheet
1,2 on 1,2 mm copper sheet
Small motors used in various components of motor vehicles often require precise and reliable welded joints. Copper welding with a blue diode laser can be used in various areas of the automotive sector, e.g. in the manufacture of electrical motors, sensors, control elements and battery systems.
- Welding of three copper contacts on the flattened side of the pins (Pin through sheet)
- Pin: 1 x 2,2 mm²
- Sheet: 1 mm
- Blue Diode Laser LDFblue 3000-30
- Welding of six Pins (Pin to Wire)
- Pin: 1 x 1 mm²
- Wire: Ø 0,9 mm
- Blue Diode Laser LDMblue 1800-30
The high absorption capacity of the blue diode laser is advantageous for a wide range of applications and materials, not just copper. Different materials with different properties can be combined without reducing the quality of the weld seam.
Typical material mixtures:
- Special coatings, e.g. gold, nickel
- Material mix, e.g. steel, copper
- Other materials, e.g. steel, titanium, non-metals
0,2 mm copper on 0,3 mm nickel plated steel
0,2 mm to 3 mm gold-coated copper
Laser brazing with the blue diode laser enables a precise and tight connection of copper pipes and fittings, for instance. The filler material used is a solder with a melting temperature below that of copper. In laser brazing, the heat is applied via a laser spot adapted to the geometry of the component. The homogeneous top hat profile of the blue diode laser ensures uniform heating. Only the brazing alloy melts, fills the brazing gap and thus joins the copper components.
- Process temperature > 450°C
- Medium power range, e.g. 0,5 to 1 kW
- Process time of 2 seconds or more
- High flexibility in the geometric design of the joint
- Targeted energy input
- Good automation and controllability
Simple and robust process due to high absorption capacity and large spot size.
Overcomes gaps, misalignments and part tolerances.
4 kW laser power | Hairpins
Simple and robust process
High absorption and large spot sizes
Accepts gaps, offsets and component tolerances
Short process times due to immediate melt pool formation
Gap 600 µm
Side offset 1,5 mm
Height offset 1,5mm
The blue diode laser can be used for stripping insulating layers from hairpins. This process is necessary in order to be able to carry out the subsequent contacting of copper ends. Normally, scanner-optics are used. Thereby, the area to be stripped is scanned with the laser-spot and the insulation is removed in one or more steps.
Which laser solutions are particularly suitable for copper laser welding and for processing gold and other non-ferrous metals? You can find a selection here.
