Advancements in laser material processing, particularly in EV battery production, require innovative solutions. Dynamic beam control of fiber lasers has emerged as a promising technology to meet these needs. This contribution examines the challenges in EV battery production and the solutions provided by these lasers. Through dynamic beam control, fiber guided lasers enable precise and efficient welding of copper and aluminum components. Adjustable beam parameters such as intensity, shape, and size enhance precision, productivity, and material utilization. These capabilities of dynamic beam-controlled lasers drive innovation in manufacturing processes for the EV industry and beyond.
In the present paper we present advances on BrightLine Weld technology addressing following three topics: A) the novel implementation of beam shaping of CW high power laser in the visible wavelength range. Due to the higher absorption in this wavelength range, applications related to welding of copper, copper alloys and gold profit from this modality. We demonstrate thereby the increase of process window in welding of copper with a 3kW laser power at wavelength of 515nm, B) the combination of BrightLine Weld with multi-spot technology for welding of casted aluminum parts. With the presented strategy gas-tight welding of the aluminum alloys for parts like casted power electronics housings, heat exchangers and extrusion profiles is enabled. C) advantages that arise by dynamically changing the split-ratio of the laser power between core and ring during the welding process while utilizing the full available power of the laser. Thereby dynamic beam shaping reduces the process time and increases the quality at the same time. We demonstrate how a fast process like welding of copper hairpin with an NIR high-power laser benefits from this modality.
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