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Why is Laser Welding of Copper and Aluminum Very Difficult?

I believe many friends have encountered the situation of laser welding of copper and aluminum to some extent. Laser welding of copper and aluminum is a challenging task because these two metals have a lower melting point, good thermal conductivity, high thermal diffusion coefficient, and are prone to thermal deformation and oxidation. Here are some key points for copper and aluminum laser welding:

1. Control heat input: Due to the good thermal conductivity and high thermal diffusion coefficient of copper and aluminum, it is necessary to control the heat input during laser welding to avoid generating excessive heat that can cause thermal deformation and oxidation.

2. Preheating: Before laser welding, copper and aluminum can be preheated to increase their temperature, reduce the thermal stress generated during the welding process, and thus reduce thermal deformation.

3. Protective gas: During laser welding, it is necessary to use protective gases such as argon or nitrogen to prevent oxidation of copper and aluminum. The flow rate, pressure, and quality of the protective gas need to meet the requirements to ensure the quality and stability of the weld.

4. Welding parameters: Suitable welding parameters need to be selected based on the material, thickness, and welding requirements of copper and aluminum, including laser power, welding speed, defocus amount, etc.

5. Welding position: Laser welding of copper and aluminum can use different welding positions such as butt joint, lap joint, or corner joint. It is necessary to choose the appropriate welding position based on the actual situation to ensure the quality and stability of the weld seam.

6. Cooling device: During the welding process, a cooling device can be used to cool the welding area to reduce the thermal stress generated during the welding process and minimize thermal deformation.

It should be noted that laser welding of copper and aluminum requires strict control of various parameters to ensure the quality and stability of the weld seam. At the same time, it is necessary to choose appropriate welding methods and processes based on the actual situation to achieve the best welding effect.