Welding reflective materials such as copper or aluminum with infrared lasers is a frustrating endeavor. The process takes a long time, and is rather inefficient overall. In fact, approximately 90% of the energy from an infrared laser will bounce off of aluminum as you’re trying to weld it. So, what to do? Thankfully, green laser welding systems eliminate these drawbacks.
Why are green lasers better for welding reflective materials?
- Shorter wavelengths, roughly half of a typical infrared laser.
- Quicker and more efficient, since more of the green laser’s energy is absorbed by the component.
- Create uniform, repeatable results.
- Low spatter formation.
Green lasers, green transportation
While green lasers have solved lots of challenges in recent times, one very popular application is EV batteries. Specifically, connectors and busbars. Copper and aluminum are sought after in battery assemblies for their conductivity, but they are also among the most reflective metals, and challenging to weld. This is just one of the challenges to overcome as automobile OEM’s race to build a higher performing EV battery.
Here at Joining Technologies, that challenge is an opportunity to help automotive manufacturers build a better battery, and meet ever-growing product demand in the most efficient way possible.
A green laser excels at welding reflective materials, doing so efficiently, without creating spatter, and without making contact. Controlled heat affected zones prevent the interior contents of the battery from being disturbed.
The reliable results achieved using green laser welding translates to more batteries produced in a shorter window. Manufacturers meet demand while decreasing costs. Further, reduced manufacturing costs means more competitive price tags. Thanks to the higher quality of the welds, and the ability to work with conductive materials, batteries are much more efficient and hold a charge for an extended amount of time. Welding innovations like this are allowing electric cars to go greater distances before needing a recharge.
What else can a green laser do?
Green laser welding systems can handle a lot more than welding copper contacts. It does very well with aluminum, which is highly reflective. It’s a popular material, since it’s generally cheaper, and weighs less than many alternatives. The green laser process enables components, such as electronics enclosures used in aerospace, to move through production much faster.
Why outsource green laser for welding reflective materials?
It might be tempting to bring this capability in house. But when it comes to using a green laser for welding reflective materials, there are many reasons to outsource.
- Demand for the laser machinery is high, but supply is tight.
- Green lasers are costly to operate and maintain.
- Higher volume runs require multiple lasers. Did we mention they were hard to get?
- When working with a welding supplier, you benefit from collaborating with designers and engineers that fully understand green’s capabilities, and more importantly, its limitations.
So, if the job calls for welding reflective materials, consider green laser welding as the best choice. The products will benefit from stronger, durable and more reliable welds, while the efficiency delivered by the process will decrease manufacturing costs.
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