Characterization of Vapor Capillary Geometry in Laser Beam Welding of Copper with 515 nm and 1030 nm Laser Beam Sources by Means of In Situ Synchrotron X-ray Imaging

Laser welding of copper is being used with increasing demand for contacting applications in electric components such as batteries, power electronics, and electric drives. With its local, non-contact energy input and high automation capability enabling reproducible weld quality, this joining technology represents a key enabler of future mobility systems. However, a major challenge in process design is the combination of energy efficiency and precise process guidance in terms of weld seam depth and defect prevention (i.e., spatter and melt ejections) due to the high electrical and thermal conductivity of copper. High-power lasers in the near infrared wavelength range ( ≈ 1 μm) and excellent beam quality provide an established joining solution for this purpose; nevertheless, the low absorptivity (≤5%) advocates novel beam sources at visible wavelengths due to altered absorptivity (40% at 515 nm) characteristics as an improved tool. In order to understand the influence of laser wavelength and process parameters on the vapor capillary geometry, in situ synchrotron investigations on Cu-ETP with 515 nm and 1030 nm laser sources with the same spot diameter are compared. The material phase contrast analysis was successfully used to distinguish keyhole and melt pool phase boundaries during the welding process. A significantly different sensitivity of the keyhole depth in relation to the feed rate was found, which is increased for the infrared laser. This behavior could be attributed to the increased effect of multiple reflections at 1030 nm