Investigation of Intermetallics Formation and Joint Performance of Laser Welded Ni to Al

In this paper, laser welding Ni to Al using pulsed wave (PW) and continuous (CW) lasers was investigated. Weld quality strength were evaluated in terms of cross-section examination, intermetallic compounds formation, microhardness, shear test 90-degree peel test. The results show that deep penetration causes high melting pool temperature severe material mixing, which could result dominant AlNi3 AlNi intermetallics (IMCs) the weld. These IMCs significantly increase hardness zone, but also lead formation defects, as well reducing ability withstand force applied comparison, process optimization maintain a shallow or form weld-braze joint, low minimum mixing can be achieved. Hence, low-hardness Al3Ni are prevalent This helps generate defect-free dissimilar weld joint higher force. findings promising applications, such battery management system electric vehicles, joining adaptor an bus bar is required.