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https://doi.org/10.1007/s40194-024-01734-4
RESEARCH PAPER
Abstract
Bead-on-plate welding of pure copper with a blue-IR hybrid laser was conducted to achieve a spatter suppression in deep
penetration welding of pure copper for the performance improvement of battery and power device of e-mobility. This hybrid
laser combines an infrared (IR) laser and a blue diode laser as the welding source and preheating source, respectively. Preheat-
ing increases the light absorptivity of pure copper in the IR region. A 1.5-kW blue diode laser was employed to increase the
light absorptivity by changing the phase of the preheated area from solid phase to liquid and gas phase. By experimentally
investigating the influence of the blue diode laser intensity, the phase effects of the preheated area on pure copper welding
with a blue-IR hybrid laser are elucidated. As a result, it was found that a liquid preheated area minimizes spatter during
deep penetration welding.
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Welding in the World
IR laser. A high-intensity IR laser is also problematic for The temperature of the preheating area was around 1000 K,
deep penetration due to the temperature dependence of which is below the melting point of copper [16].
light absorptivity of pure copper in the IR region. The To suppress spatters in deep penetration welding, we
absorptivity gradually increases with temperature, but a considered that the absorptivity of pure copper must be
jump occurs near the phase transition from a solid to a liq- further increased. Therefore, we used a 1.5-kW class blue
uid [10]. This effect induces a sudden increase in the heat diode laser as a preheating source. This allowed melting
input, which leads to sudden evaporation of the molten or vaporization of preheated copper as the preheated area
pool while welding with a high-intensity IR laser. Conse- undergoes a phase transition. If the phase of the preheated
quently, the molten pool and keyhole become unstable in area changes to a liquid or gas phase, the light absorptivity
keyhole mode welding with a high-intensity IR laser. This in the IR region should be higher than that in the solid phase
generates spatters, which reduces the strength of the weld- [10]. This should inhibit the jump in the light absorptivity
ing part and damages areas surrounding the welding part. that accompanies the phase change from solid to liquid when
Blue diode lasers are attracting attention as a solution welding with an IR laser, which is one source of spatter gen-
to these issues. Blue diode lasers have a wavelength of eration. Therefore, using a 1.5-kW class blue diode laser for
450 nm, and pure copper has a high light absorptivity for preheating should suppress spatters.
this wavelength [9]. Morimoto et al. reported that the light Herein, bead-on-plate welding was conducted with a
absorptivity of pure copper shows a small temperature blue-IR hybrid laser using a 1.5-kW class blue diode laser
dependence for blue lasers compared to that for the IR preheating to realize spatter suppression in deep penetra-
region [11]. Due to these advantages, some researchers tion welding of pure copper. The effect of the phase of the
have reported the effectiveness of blue diode lasers for preheated area while welding pure copper with a blue-IR
copper processing and clarified that a highly efficient heat hybrid laser was experimentally investigated. Specifically,
input can be conducted for pure copper [12–14]. However, the phase of the preheated area was changed by varying
the output power and beam quality of current blue diode the intensity of the blue diode laser. Then, the molten pool
lasers are inferior to those of IR lasers such as a fiber or behavior and spatters were observed during welding. Addi-
disk laser. tionally, a cross-sectional image of the bead was analyzed
A blue-IR hybrid laser was developed to realize high- after welding.
quality laser welding of pure copper. This hybrid laser com-
bines a single-mode fiber laser with a blue diode laser. The
blue diode laser serves as a preheating source to increase the 2 Experimental setup
light absorptivity of pure copper for the IR laser. Previously,
this blue-IR system with a 200-W class blue diode laser pre- Figure 1 schematically depicts the experimental setup. A 1.5-
heating was used to weld pure copper. Although blue diode kW single-mode fiber laser (Furukawa Electric) was used
laser preheating increased the penetration depth of pure as a welding source, and a 1.5-kW blue diode laser (Shi-
copper, spatters remained in deep penetration welding [15]. madzu) was used as a preheating source. The specifications
of this blue diode laser are reported in the literature [17]. more detail, the mass of the pure copper sample was meas-
The single-mode fiber laser was collimated by an f50-mm ured before and after laser welding to evaluate the mass loss.
plano-convex lens, focused by an f150-mm plano-convex The intensity of the blue diode laser was varied during
lens, and irradiated vertically onto a sample. Additionally, the welding test. In the preliminary experiment, pure copper
the blue diode laser was collimated by an f100-mm achro- was irradiated with only a blue diode laser to identify the
matic lens and focused by an f75-mm achromatic lens. The intensity of the blue diode laser that induces a phase transi-
blue diode laser was irradiated onto the sample at an incident tion in the preheated area. In the subsequent experiment, a
angle of 45°. single-mode fiber laser was combined with a blue diode laser
Table 1 shows the experimental conditions. In the exper- to conduct blue-IR hybrid laser welding. Afterwards, the
iments, each laser was focused on the top surface of the sample was cut, polished, and etched with 10% hydrochloric
sample at the focal point. The spot size was set at x, 55 µm acid and iron(III) chloride. Then, the cross-section of the
and y, 54 µm, for the single-mode fiber laser and x, 424 µm bead was observed with an optical microscope (VHX-5000,
and y, 300 µm, for the blue diode laser. Each laser spot was KEYENCE).
centered and combined at the processing point. The inten- After the bead-on-plate welding test, lap welding of two
sity of the single-mode fiber laser was set at 0 or 42.1 MW/ 1-mm-thick pure copper plates was demonstrated with the
cm2, while that of the blue diode laser was varied from 0 to blue-IR hybrid laser. Figure 3 depicts the lap welded sam-
1.14 MW/cm2. Both lasers were irradiated simultaneously ple. The pure copper plate measured 30 m mw × 100 mml × 1
t
by a pulse generator (DG535, Stanford Research Systems). mm . The laser was scanned on the center of lapped part for
Figure 2 schematically shows the bead-on-plate weld- 25 mm at 100 mm/s. The intensity of the single-mode fiber
ing test of a pure copper plate. While irradiating, the laser laser was set at 50.5 MW/cm2, while the intensity of the
spots were scanned for 25 mm on a 2-mm-thick pure copper blue diode laser was varied. Three samples were prepared
sample by a linear stage at a scanning speed of 100 mm/s. for each condition.
High-speed video camera 1 (Q1v, NAC) at an angle of 45° Next, the ultimate shear strength (USS) was determined.
from the horizontal observed a molten pool during laser First, the joined samples were cut into 15 m mw × 60 mml × 1
irradiation. To observe the molten pool, laser light entering mmt pieces. Second, USS was measured using a universal
high-speed video camera 1 was cut by equipping it with a
long-pass filter at a 560-nm wavelength and a short-pass
filter at a 900-nm wavelength. High-speed video camera 2
(HX-3, NAC) from a direction perpendicular to the laser
scanning direction observed the spatters. Spatters generated
during welding were counted one by one from the captured
image. The spatter rate was determined by dividing the total
number of spatters generated while welding by the laser
scanning length. Table 2 lists the observation conditions of
each camera. To analyze the spatter generation behavior in
Fig. 4 Time elapses of the blue diode laser irradiation spot with the intensity of a 0.21 MW/cm2, b 0.42 MW/cm2, c 0.64 MW/cm2, d 0.85 MW/
cm2, e 1.06 MW/cm2, and f 1.14 × 106 W/cm.2
3.2.2 Melting and solidification dynamics of pure copper increased from 0 to 0.85 MW/cm2. Once the laser intensity
reached 0.85 MW/cm2, the phase of the preheated area is a
While welding with blue-IR hybrid laser, spatters were liquid, the spatter rate decreased about 90% compared to that
observed from the horizontal direction by the high-speed of 0 MW/cm2. However, an increased spatter rate accompa-
video camera. Figure 9 shows the spatter rate and the mass nied the phase transition of the preheated area from a liquid
loss of sample for different blue diode laser intensities. to a gas. The mass loss trend was consistent with that of the
The spatter rate decreased as the blue diode laser intensity spatter rate.
Welding in the World
Fig. 9 Spatter rate and mass loss for different blue diode laser intensi-
ties while blue-IR hybrid laser welding of pure copper
Fig. 10 Melting and solidification dynamics of pure copper weld- 0 MW/cm2, b 0.21 MW/cm2, c 0.85 MW/cm2, and d 1.14 MW/cm2
ing at a scanning speed of 100 mm/s with a blue-IR hybrid laser and for the blue diode laser
parameters of 42.1 MW/cm2 for the single-mode fiber laser and a
the single-mode fiber laser only), (b) 0.21 MW/cm2, (c) 1 ∑8 || Wka,q − Wave ||
0.85 MW/cm2, and (d) 1.14 MW/cm2. It should be noted that FR = | | × 100 (2)
8 q=1 || Wave |
these values coincide with a phase change of the preheated |
area when welding with a blue diode laser only. When the Wave is the average value of Wka from 0.01 to 0.08 s.
single-mode fiber laser was irradiated onto the pure copper Wka,1, Wka,2 , …, and Wka,8 mean Wka at 0.01 s, 0.02 s, …,
with (a) 0-MW/cm2 and (b) 0.21-MW/cm2 blue diode laser, and 0.08 s, respectively. Figure 11 shows FR for different
the preheated area was in the solid phase and spatters along blue diode laser intensities along with the phase of the
with the ejection of the molten pool were observed. Using preheated area. As the blue diode laser intensity increased,
(c) 0.85-MW/cm2 blue diode laser, the preheated area was FR decreased in the region from 0 to 0.85 MW/cm2 but
liquid. An ejection of molten pool was not occurred, and increased from 0.85 to 1.14 MW/cm2. The average value of
only a few spatters were observed. Using (d) 1.14-MW/cm2 FR for each phase of the preheated area was 23.2%, 9.2%,
blue diode laser, the preheated area was in the gas phase, and 19.8% for the solid, liquid, and gas phase, respectively.
and the fluctuations of the molten pool surface increased. Hence, FR decreased when the preheated area was a liquid.
In addition, the keyhole aperture repeatedly expanded and However, FR increased when the keyhole was formed and
contracted. Not only was spatter generation observed but a the preheated area was in the gas phase.
plume also formed intermittently while welding. The trends of the spatter rate and FR for each phase of
From the captured images, the width of the keyhole aper- the preheated area were consistent. Next, we considered
ture (Wka) parallel to the laser scanning direction was meas- the variation mechanism of FR and spatter generation with
ured at different times. The fluctuation rate of Wka (FR) was respect to the phase transition of the preheated area.
obtained to evaluate the fluctuation of the keyhole aperture
for a given blue diode laser intensity. FR is defined as
Welding in the World
Fig. 12 Schematics of the keyhole dynamics while welding pure copper with a blue-IR hybrid laser when the preheated area is (a) solid, (b) liq-
uid, and (c) gas
Welding in the World
Declarations of thin copper parts using real-time control. In: Proc. SPIE 4977,
photon processing in microelectronics and photonics II
Conflict of interest The authors declare no competing interests. 11. Morimoto K, Tsukamoto M, Masuno S, Azumi K, Hayafshi Y,
Abe N (2019) Influence of laser wavelength on melt pool behav-
Open Access This article is licensed under a Creative Commons Attri- ior in welding of thin pure copper plate with blue diode and fiber
bution 4.0 International License, which permits use, sharing, adapta- lasers. In: Proc. lasers in manufacturing conference 2019
tion, distribution and reproduction in any medium or format, as long 12. Ono K, Sato Y, Higashino R, Funada Y, Abe N, Tsukamoto M
as you give appropriate credit to the original author(s) and the source, (2020) Pure copper rod formation by multibeam laser metal depo-
provide a link to the Creative Commons licence, and indicate if changes sition method with blue diode lasers. J Laser Appl 33:012013
were made. The images or other third party material in this article are 13. Takazawa Y, Sato Y, Takenaka K, Yamashita Y, Kunimine T, Tsu-
included in the article’s Creative Commons licence, unless indicated kamoto M (2023) High speed coating for pure copper by multi-
otherwise in a credit line to the material. If material is not included in beam laser metal deposition method with high intensity blue diode
the article’s Creative Commons licence and your intended use is not lasers. J Laser Appl 35:012029
permitted by statutory regulation or exceeds the permitted use, you will 14. Zapico EP, Ascari A, Fortunato A, Liverani E, Dimatteo V (2022)
need to obtain permission directly from the copyright holder. To view a Influence of process parameters in blue laser welding of copper
copy of this licence, visit http://creativecommons.org/licenses/by/4.0/. and aluminum thin sheets. J Laser Appl 34:042039
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