Characterization of dissimilar aluminum-copper material joining by controlled dual laser beam

Laser welding affords many advantages during the manufacture of EV battery packs. Aluminum (Al) and copper (Cu) are welded using a dual laser beam with core ring different powers. Given very high reflectance Cu Al exposed to near-infrared lasers, materials absorb only small amounts energy. Compared single-beam welding, dual-beam significantly improves surface quality by controlling solidification. Here, we focused on beads, weld properties, tensile strength; varied output ratio beam. The optimal conditions for Al6061 were 700-W beam, 500 W speed 200 mm/s. For C1020P, center 2500 W, 3000 During lap Al-Al Al-Cu, bead width interfacial joint increased as increased. penetration depth did not change, but pores formed at interface junction. Tensile tests performed demonstrate reliability zone; computer simulations analyze heat distributions under input conditions.