Novel Opportunities by Laser Welding of Dissimilar Materials

The Laser Technology Competence Centre (LTCC) of the University of Luxembourg provides skills in joining material combinations, which are considered being non-weld able with traditional methods or at least challenging to join (e.g. Copper and Aluminium, Aluminium and Polyamide (PA), Titanium and PEEK, steel and tungsten hard alloy). Related accomplishments include minimal intermetallic compounds, convincing mechanical and superior electrical properties of the laser-welded specimen.
With defined spatial and temporal modulation of the laser beam, an accurately defined temperature profile is created on the lower side of the upper material in the two dimensional directions, which enable joining of dissimilar materials in overlap configurations, despite challenging thermal properties.
To weld butt-joint geometries with minimal heat affected volume, the temperature profiles were expanded in the third dimension, which can be achieved through controlled laser energy guidance.
The scientific methods to accomplish these convincing results are explained, with selected industrial use cases ranging from automotive industry, energy storage, and medical implants.
An outlook with unsolved challenges is intended to ignite discussions about upcoming research topics.