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Spatial beam oscillation during laser beam welding of aluminum to copper was investigated. The beam was spatially oscillated perpendicular to the direction of feed in a sinusoidal mode. The influence of the oscillation amplitude and frequency on the weld seam geometry and the implications on the electrical resistance of the joints was investigated. It was found that spatial beam oscillation allows to set the welding depth and seam width virtually independent of each other. Furthermore, low welding depths into the lower copper sheet in combination with high ratios of seam width at the interface of the two sheets to welding depth into the lower copper sheet result in low electrical resistances of the welds. Low electrical resistances were found to correlate with high mechanical strengths of the welds.

Weld Seam Geometry and Electrical Resistance of Laser-Welded, Aluminum-Copper Dissimilar Joints Produced with Spatial Beam Oscillation