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Title: Laser welding of copper and aluminium alloys for electrical interconnects
Author: De Bono, Paola
ISNI:       0000 0004 5922 5431
Awarding Body: University of Birmingham
Current Institution: University of Birmingham
Date of Award: 2016
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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 auto-motability, high processing speed and highly repeatable cost-effective processing. However, laser welding of monometallic and dissimilar Cu and A1 presents several difficulties due to the high surface reflectivity at infrared (IR.) wavelengths. Three main areas were investigated in this research work: • Laser beam lap-welding of monometallic Cu sheets, with the aim of validating the developed welding procedures against target specifications addressed by the automotive industry, in line with production environment setups. • The suitability of using tailored energy distributions, produced using a 1070nm laser source delivered through a laser beam scanner, for welding multiple overlapping Al or Cu foils. • The effects of different laser processing parameters on the formation of deleterious brittle intermetallic phases when welding Alto Cu with a continuous-wave Yb-fibre laser.
Supervisor: Not available Sponsor: Engineering and Physical Sciences Research Council (EPSRC) ; TWI Ltd
Qualification Name: Thesis (D.Eng.) Qualification Level: Doctoral
EThOS ID:  DOI: Not available
Keywords: TN Mining engineering. Metallurgy