Aluminum laser welding is a well-established joining technology in the field of lightweight components and many efforts were devoted to the optimization of the process in order to achieve sound joints in different applications. The constantly growing demand of high-performance lightweight components determined, among others, the need for joining applications where different aluminum alloys, in different semi-finished conditions, are fusion-welded together for achieving optimized components that show optimum trade-offs between mechanical performance and weight. In this direction, one of the fields where those needs are particularly evident is the electro-mobility one, where the production of casings for lithium-ion batteries often requires welding of wrought sheets with components manufactured by means of additive technologies and/or high pressure die casting. According to the above-mentioned considerations, the present paper investigates the role of different laser sources in welding 5xxx wrought aluminum sheets to additive manufactured Al-Si components. The study is aimed at giving a comparison among the most important currently available laser welding solutions both in terms of beam quality and of the eventual use of beam shaping. In particular, single-mode and multi-mode sources are exploited, both in traditional single fiber and in core+ring configuration. Different beam manipulations are also used: simple linear and wobbling welding are caried out, both at high and low speeds. The results are characterized in terms of weld bead morphology, presence of cracks and pores, microstructure and dilution between the parent metals.
Keywords
- Additive Manufacturing
- Aluminum Laser Welding
- Battery Cases
- E-Mobility
- Wrought Aluminum