This paper investigates the feasibility of using a 2kW direct diode laser source for producing high-quality cuts in a variety of materials. Cutting trials were performed in a two-stage experimental procedure. The first phase of trials was based on a one-factor-at-a-time change of process parameters aimed at exploring the process window and finding a semi-optimum set of parameters for each material/thickness combination. In the second phase, a full factorial experimental matrix was performed for each material and thickness, as a result of which, the optimum cutting parameters were identified. Characteristic values of the optimum cuts were then measured as per BS EN ISO 9013:2002.
The adoption of lithium-ion and/or super-capacitor battery technologies is a current hot topic in the automotive industry. For both battery types, the terminals and busbars are manufactured from copper (Cu) and/or aluminium-based (Al-based) alloys, as a result of their high electrical and thermal conductivities. Laser welding is considered an attractive process to industry due to its easy automotability, high processing speed and highly repeatable cost-effective processing. However, laser welding of Cu-Cu and Al-Al joints presents several difficulties due to the high surface reflectivity at infrared (IR) wavelengths. This behaviour becomes even more critical when processing thin sheets and foils.This paper summarises recent work performed to develop laser welding techniques suitable for monometallic joining of Cu-Cu and Al-Al electrical interconnections. Laser welding of multiple overlapped foils (with thickness in the range of 17μm-100μm) were investigated.