Several beam sources have been proposed for use in laser welding of hairpin couples in electric drive manufacturing. Contemporary laser sources provide several options in terms of temporal and spatial beam intensity variations as well as novel wavelengths. Benchmarking studies are fundamental for providing comparative analysis in order to point out the most suitable laser solution for the given hairpin configuration in terms of size, material, and position in the electric drive. Simulation tools can be of aid to test out new laser solution especially prior to extensive experimental testing in a wider range of process parameters involving new beam shapes. This work describes the development of computer fluid dynamics simulations to understand the influence of the core and ring beam shapes in laser welding of copper hairpin couples. The work provides a systematic view of simulation setting, calibration, and validation stages. In the experimental work, a 5 kW fiber laser source with core and double coaxial ring configuration is tested. The experiments were assisted by high speed imaging. The results provide a clear view over the keyhole and pore formation with different beam shape configurations as well as allowing the future parameter sets to be more flexibly identified with simulation aids.
Keywords
- Beam Shaping
- Electric Mobility
- High Speed Imaging
- Process Simulation