Effect of focal position offset on joint integrity of AA1050 battery busbar assembly during remote laser welding

This paper aims at studying the impact of focal position offset on joint integrity AA1050 battery busbar during remote laser welding. Welding experiments were conducted different offsets in L-joint with integration beam oscillation. The was evaluated by multiple indicators including weld geometry, thermal profile, porosity and mechanical strength. Results showed that defocusing tends to be favourable for reduction peak temperatures porosity. However, a more than 3 mm can lead 60% drop bonding 40% loss A tolerance window [-2 1] determined offset, corresponding 70% 30% Rayleigh length. result is useful reference inform precise control respect accumulated variations part tolerance, part-to-part gap positioning errors. study also indicated measurement potential approach in-process monitoring integrity. Indeed, temperature near zone good linear correlation off-line detectable depth, width interface, tensile strength