Investigation on Laser Welding of Al Ribbon to Cu Sheet: Weldability, Microstructure, and Mechanical and Electrical Properties

The pulsed laser welding of Al ribbon to Cu sheet was investigated for the electrical interconnections in power electronic modules. various experimental conditions with different powers, scan speeds, and heat inputs were employed obtaining defect-free Al/Cu joints. During welding, intermetallic compounds formed zone. An electron probe microanalyzer transmission microscopy confirmed phases compounds, which found be Al4Cu9, Al2Cu, AlCu, etc. computational fluid dynamics simulation revealed that Marangoni effect induced circulation molten pool, resulting mixture formation swirl-like structures at tensile shear strengths resistances joints measured, they showed a strong correlation area. A decrease mechanical strength an increase resistance measured increasing area Moreover, process window developed, braze-welding examined minimize