Laser Welding of Dissimilar Materials with 1kW Fiber Laser

The majority of applications in a range of industries i.e. automotive, electronics and medical, require welding of dissimilar materials. In principle, a laser can weld any material, which can then be joined by conventional processes.

When welding dissimilar metals, good solid solubility is essential for sound weld properties. The trends of welding dissimilar metals present considerable challenges. The weldability of dissimilar metals depends on many factors. The physical properties have a high influence on the amount of energy coupled in and the heat transfer.

When joining dissimilar materials, there may be certain advantages in using laser welding even though brittle intermetallics can form. Since the weld itself is narrow, the volume of intermetallics may be reduced to acceptable limits. Again, it may be possible to offset the beam in one direction or another, thus allowing some control over composition of the resulting alloy.

Although it may be possible to produce sound joints using these methods on a laboratory scale, it is more difficult to achieve similar controls under production conditions. This paper presents welding results achieved with a 1kW fiber laser for a range of materials.

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