The integration of additive manufacturing’s design versatility with a push for electrification can lead to unique innovations. In this context, when discussing welded joints, their quality and reliability play a significant role. The restricting factor for the use of laser powder bed fusion of metal (PBF-LB/M) additive manufactured (AM) parts is often their surface quality in the as-built state. In addition, the surface quality changes when part plane orientation changes. In this study AlSi10Mg aluminum test samples were additive manufactured in seven different build angles. The AM samples were glass bead blasted after manufacturing and the surface roughness of the joint surface area was optically measured. After the measurement, the AM samples were welded to nickel-plated copper and aluminum sheet metals. A continuous wave single-mode fiber laser with scanner optics was used to carry out the welding experiments in lap joint configuration. The structural and mechanical properties of the welds were evaluated by the macroscopic images of weld cross sections and tensile testing of the samples. The electric resistivity of the samples was also tested. Based on the measurement results of the samples, the impact of surface quality was discussed. The results indicated that there was no clear effect of building angle on the final weld quality. The worst surface quality in the joint area was on the test pieces in which the joint surface was facing down toward the build plate.
Keywords
- Additive Manufacturing
- Alsi10Mg Aluminium
- Battery
- Laser Welding
- Surface Roughness