To design future laser manufacturing processes for welding of copper materials, more and more high-end analysis methods are required. A fundamental process understanding by analyzing cause-and-effect relations of process dynamics using inline in situ diagnostics allows for an improved description of laser material interaction. Strategies for a reliable and robust welding process are derived from the findings. In this study, a four-step advanced methodical approach is presented and discussed. In the first step, a fundamental process description of the geometry of the vapor capillary and the formation of weld defects is developed. Therefore, welds on electrolytic tough pitch copper (Cu-ETP) and CuSn6 are carried out to analyze the temporal and spatial vapor capillary dynamics depending on laser power, welding speed, and focal diameter. This fundamental process understanding is transferred to the welding of copper pins in the form of I-pins. For this purpose, impurities and imperfections were applied to the pin surface to investigate the effects on the process result. As a third step, strategies by means of laser intensity distributions were adapted to compensate for imperfections in the welding process. Finally, a sensor vision system is adapted for ideal welding results. Investigations are based on in situ synchrotron analysis at Petra III, DESY in Hamburg. For the experiments, a TRUMPF TruDisk laser (100/400 μm fiber diameter), a TRUMPF TruFiber 6000P (50/100 μm fiber diameter), and a single-mode fiber laser (14 μm fiber diameter) were used. The focal diameter was adjusted with the optical system depending on the investigation.
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November 2024
Research Article|
September 03 2024
Development workflow based on in situ synchrotron investigations to optimize laser processing of copper pins
Marc Hummel
;
Marc Hummel
(Conceptualization, Data curation, Formal analysis, Investigation, Methodology, Validation, Visualization, Writing – original draft, Writing – review & editing)
1
TRUMPF Laser- und Systemtechnik SE
, Johann-Maus-Straße 2, Ditzingen 71254, Germany
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Christoph Spurk
;
Christoph Spurk
a)
(Conceptualization, Data curation, Formal analysis, Investigation, Methodology, Validation, Visualization, Writing – original draft, Writing – review & editing)
2
RWTH Aachen University, Chair for Laser Technology LLT
, Steinbachstraße 15, Aachen 52074, Germany
a)Author to whom correspondence should be addressed; electronic mail: christoph.spurk@llt.rwth-aachen.de
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Andreas Heider
;
Andreas Heider
(Conceptualization, Formal analysis, Investigation, Methodology, Visualization, Writing – original draft)
3
Robert Bosch GmbH, Corporate Research
, Robert-Bosch-Campus 1, Renningen 71272, Germany
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Matthias Beranek;
Matthias Beranek
(Conceptualization, Data curation, Formal analysis, Funding acquisition, Investigation, Methodology, Supervision, Validation, Visualization, Writing – original draft, Writing – review & editing)
1
TRUMPF Laser- und Systemtechnik SE
, Johann-Maus-Straße 2, Ditzingen 71254, Germany
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André Häusler
;
André Häusler
(Conceptualization, Methodology, Resources, Supervision, Writing – original draft)
4
Fraunhofer Institute for Laser Technology ILT
, Steinbachstraße 15, Aachen 52074, Germany
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Mauritz Möller
;
Mauritz Möller
(Conceptualization, Investigation, Methodology, Project administration, Resources, Supervision, Validation, Writing – original draft)
1
TRUMPF Laser- und Systemtechnik SE
, Johann-Maus-Straße 2, Ditzingen 71254, Germany
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Felix Beckmann
;
Felix Beckmann
(Resources, Supervision)
5
Helmholtz Center HEREON, Institute of Materials Physics
, Max-Planck-Str. 1, Geesthacht 21502, Germany
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Julian Moosmann
Julian Moosmann
(Resources, Supervision)
5
Helmholtz Center HEREON, Institute of Materials Physics
, Max-Planck-Str. 1, Geesthacht 21502, Germany
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a)Author to whom correspondence should be addressed; electronic mail: christoph.spurk@llt.rwth-aachen.de
J. Laser Appl. 36, 042001 (2024)
Article history
Received:
July 01 2024
Accepted:
August 13 2024
Citation
Marc Hummel, Christoph Spurk, Andreas Heider, Matthias Beranek, André Häusler, Mauritz Möller, Felix Beckmann, Julian Moosmann; Development workflow based on in situ synchrotron investigations to optimize laser processing of copper pins. J. Laser Appl. 1 November 2024; 36 (4): 042001. https://doi.org/10.2351/7.0001596
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