Copper welding has been revolutionized by the development of a new blue diode laser. The blue laser beam copper and other non-ferrous metals to undergo high-quality processing within industrial processes.
For the first time, the blue laser makes it possible to undertake controlled heat conduction welding of copper and other non-ferrous metals with low material thicknesses: material thicknesses of less than one millimeter are no longer a problem. While 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 melts the desired material along the joints, then the liquefied materials flow into each other and form the weld seam when they cool down. This process results in particularly smooth seams that are of outstanding quality and, therefore, highly stable. In principle, the process is the same as with an infrared laser – apart from the wavelength used.
Welding of Copper Pins with a Blue Diode Laser
Welding of two copper pins (approx. 0.5x1.5mm²) with 450nm wavelength and 100ms pulse time for electrical applications.
Heat conduction welding with the blue diode laser leads to a very stable, homogeneous molten pool without any evaporation. The dominant surface tension of the liquid copper bridges the gaps between the pins, resulting in a homogeneous connection.
Bead on plate weld on a pure copper sheet (0.5mm thickness) with the Laserline LDMblue 500-60.
Heat conduction welding with a wavelength of 450 nm and a focus diameter of 600 µm ensures a highly stable molten pool without spatters during the welding process.
Laser: LDMblue 500-60
Copper sheet: 0.5mm
Focus diameter: Ø0.6mm
In our series “Diode lasers and their applications”, we offer a regular insight into the most important applications based on diode lasers. And one field of application, in particular, should not be forgotten: copper welding.
But why is this special application so important? Copper is one of the most important raw materials for electrical signal transmission and thus a key component of many modern technologies. In battery cells of mobile devices, in induction coils or in accumulators of electric cars, copper segments can today be found everywhere. Often the components are exposed to a high current, high operating temperatures and strong vibrations. This significantly affects the production process: When components are made of several parts, the joining seams must be highly solid and must not create additional resistances in the signal flow to prevent an increased temperature in the component. As brazed joints often lack the required head resistance, weld seams created by lasers are the best option here.