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@ARTICLE{Kaufmann:622961,
author = {Kaufmann, Florian and Schrauder, Julian and Hummel, Marc
and Spurk, Christoph and Olowinsky, Alexander and Beckmann,
Felix and Moosmann, Julian and Roth, Stephan and Schmidt,
Michael},
title = {{T}owards an {U}nderstanding of the {C}hallenges in {L}aser
{B}eam {W}elding of {C}opper – {O}bservation of the
{L}aser-{M}atter {I}nteraction {Z}one in {L}aser {B}eam
{W}elding of {C}opper and {S}teel {U}sing in {S}itu
{S}ynchrotron {X}-{R}ay {I}maging},
journal = {Lasers in manufacturing and materials processing},
volume = {11},
number = {1},
issn = {2196-7229},
address = {New York, NY [u.a.]},
publisher = {Springer},
reportid = {PUBDB-2025-00597},
pages = {37 - 76},
year = {2024},
abstract = {The increasing demand for contacting applications in
electric components such as batteries, power electronics and
electric drives is boosting the use of laser-based copper
processing. Laser beam welding is a key for an efficient and
high-quality electric vehicle production due to its local,
non-contact energy input and high automation capability
enabling reproducible weld quality. Nevertheless, a major
challenge in process design is the combination of
energy-efficiency and precise process guidance with regard
to weld seam depth and defect prevention (i.e. spatter, melt
ejections), partly caused by the high thermal conductivity
of copper. High power lasers in the near infrared range and
emerging visible laser beam sources with excellent beam
quality can provide a suitable joining solution for this
purpose. However, the underlying physical phenomena are
currently only partly understood and a reflection on the
challenges of laser beam welding of copper compared to well
researched steel processing has not yet been carried out. In
order to improve the understanding of the effect of the
different material properties and the influence of process
parameters on the vapor capillary and melt pool geometry in
laser beam welding, in situ synchrotron investigations on
Cu-ETP and S235 using 515 and 1030 nm laser sources were
conducted. The material phase contrast analysis was
successfully used to distinguish vapor capillary and melt
pool phase boundaries during the welding process with high
spatial and temporal resolution up to 5 kHz. A significantly
different vapor capillary geometry and sensitivity to
parameter variation were found between the steel and copper
material. In addition, the visualization of characteristic
melt flows revealed different melt pool dynamics and a
pronounced eddy close to the melt pool surface for copper,
which is assumed to be causal for the observation of
pronounced spatter formation during copper welding in a
certain process window.},
cin = {DOOR ; HAS-User / Hereon},
ddc = {670},
cid = {I:(DE-H253)HAS-User-20120731 / I:(DE-H253)Hereon-20210428},
pnm = {6G3 - PETRA III (DESY) (POF4-6G3) / DFG project
G:(GEPRIS)434946896 - FOR 5134: Erstarrungsrisse beim
Laserstrahlschweißen: Hochleistungsrechnen für
Hochleistungsprozesse (434946896) / SFB 1120 A13 -
Vereinheitlichte partikelbasierte Simulation von
Schmelzströmungen und Erstarrungsprozessen unter
Berücksichtigung von thermoelasto-viskoplastischem
Festkörperverhalten zur Erhöhung der Präzision (A13*)
(504046910) / FS-Proposal: I-20210713 (I-20210713)},
pid = {G:(DE-HGF)POF4-6G3 / G:(GEPRIS)434946896 /
G:(GEPRIS)504046910 / G:(DE-H253)I-20210713},
experiment = {EXP:(DE-H253)P-P07-20150101},
typ = {PUB:(DE-HGF)16},
UT = {WOS:001503058600009},
doi = {10.1007/s40516-023-00225-6},
url = {https://bib-pubdb1.desy.de/record/622961},
}