Riassunto analitico
The welding of aluminium and copper has been
the subject of extensive research for several decades, as the lack of a single
ideal material makes it necessary to join different materials. Whilst optimal
materials have desirable properties for specific applications, they often have
significant disadvantages, requiring the integration of additional materials to
compensate for these limitations. This challenge has fuelled the development of
advanced welding techniques that can be used to join not only different metals,
but also metals with polymers and ceramics. However, the compatibility between
materials has a major impact on the feasibility of welding. For example, highly
compatible materials such as copper and nickel can be effectively welded in the
liquid state using conventional welding processes, while combinations such as
nickel and titanium require innovative techniques due to their limited
compatibility.
Copper-aluminium compounds have attracted
considerable interest due to their complementary properties: copper offers
exceptional thermal and electrical conductivity and corrosion resistance, while
aluminium offers lightweight properties and cost advantages. The possibility of
replacing copper with aluminium in conventional parts enables weight and cost
reductions and expands the range of applications in cable systems, battery
technology, busbars, sinkholes, and power generation systems for vehicles and electrical
appliances.
In this study, square aluminium and copper
sheets were laser welded at different power levels and exposure times to
investigate the influence of the process parameters on the microstructural
evolution at the interface. Controlled irradiation was used to facilitate joint
formation between the metals. After welding, the samples were embedded in epoxy
resin and prepared for microstructural analysis. Optical microscopy assessed
the interlayer width and depth, while scanning electron microscopy (SEM) in
conjunction with energy dispersive X-ray spectroscopy (EDS) enabled qualitative
and quantitative phase characterisation. Particular attention was given to the
morphology of the microstructure, including the measurement of lamellar spacing
within the eutectic regions. This preliminary analysis highlights the
sensitivity of the microstructural features to the process parameters and
provides valuable insights for the optimisation of joint properties in
laser-welded Al–Cu systems.
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Abstract
The welding of aluminium and copper has been
the subject of extensive research for several decades, as the lack of a single
ideal material makes it necessary to join different materials. Whilst optimal
materials have desirable properties for specific applications, they often have
significant disadvantages, requiring the integration of additional materials to
compensate for these limitations. This challenge has fuelled the development of
advanced welding techniques that can be used to join not only different metals,
but also metals with polymers and ceramics. However, the compatibility between
materials has a major impact on the feasibility of welding. For example, highly
compatible materials such as copper and nickel can be effectively welded in the
liquid state using conventional welding processes, while combinations such as
nickel and titanium require innovative techniques due to their limited
compatibility.
Copper-aluminium compounds have attracted
considerable interest due to their complementary properties: copper offers
exceptional thermal and electrical conductivity and corrosion resistance, while
aluminium offers lightweight properties and cost advantages. The possibility of
replacing copper with aluminium in conventional parts enables weight and cost
reductions and expands the range of applications in cable systems, battery
technology, busbars, sinkholes, and power generation systems for vehicles and electrical
appliances.
In this study, square aluminium and copper
sheets were laser welded at different power levels and exposure times to
investigate the influence of the process parameters on the microstructural
evolution at the interface. Controlled irradiation was used to facilitate joint
formation between the metals. After welding, the samples were embedded in epoxy
resin and prepared for microstructural analysis. Optical microscopy assessed
the interlayer width and depth, while scanning electron microscopy (SEM) in
conjunction with energy dispersive X-ray spectroscopy (EDS) enabled qualitative
and quantitative phase characterisation. Particular attention was given to the
morphology of the microstructure, including the measurement of lamellar spacing
within the eutectic regions. This preliminary analysis highlights the
sensitivity of the microstructural features to the process parameters and
provides valuable insights for the optimisation of joint properties in
laser-welded Al–Cu systems.
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