The rise of e-mobility has particularly increased the use of copper and aluminum in the series production of vehicles. The production of electric motors in particular focuses on copper-copper connections in hairpins. Due to the late position of hairpin welding in the stator’s value chain, defective welds lead to irreparable damage to the stator and thus to increased scrap costs. In addition, the focus is also on copper-aluminum connections, particularly in the area of battery contacting with high demands on the connection cross-section. The presentation will highlight the possibilities of using precise beam guidance, high deflection speeds and beam shaping to safely and robustly design automated welding processes in series production. Different welding strategies will be discussed using the example of the copper hairpin welding process and the welding of aluminum and copper contacts in battery production. Furthermore, the possibility of using beam forming technology in the beam source and the welding optics to make the processes safe and robust and to additionally improve the appearance of the welds on copper and aluminum will be discussed. Furthermore an outlook is been given which technical trends for welding especially copper in the laser branch, as well as the possibilities to use intelligent optics to ensure robust joining processes in series production.
Laser Joining of Copper-Copper and Copper-Aluminum Application in the E-Mobility
Proceedings
14.04.2021
4 pages
Aufsatz/Kapitel (Buch)
Elektronische Ressource
Englisch
Copper welding , Cu-Cu-welds , Aluminum welding , Al-Al-welds , Al-Cu-welds , Beam shaping , Beam forming , Laser , Fast laser beam movement , RLW-S , Fast scanners , Stable process , Reduced spatter , No spatter , Welding process , Scansonic , High speed beam movement , Laser process , Hairpin , Hair-pin , Stator , Electric motor , Electric engine , Process knowledge Engineering , Automotive Engineering , Engine Technology
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