Fundamental Study of Micro Welding with Continuous-Wave Laser Sources

In this section

Back to Core Research Programme AMorph – 4D Printing for Field Morphing Structures Automation of Composite and Hybrid Joining Process Coaxial Wire Additive Manufacturing Processes and In-Line Monitoring Tools Development of Coded Excitation Technique for Non-Metallic Pipes Inspection Development of Digital Twin technology as a demonstrator for real-time integrity assessment of crack growth in tensile specimens Development of Friction Stir Welding (FSW) for Hydrogen Fuel Storage Tanks Development of Leak-Before-Break Hydrogen Storage Composite Pressure Vessels With Polymeric Liner Establishing Assessment Methods for Determining Safe Service Limits of High-Temperature Materials in Extreme Environments Fracture toughness in aggressive environments: effect of crack monitoring techniques on test results In-process detection and non-destructive testing of electron beam weld imperfections Internal Bore Coatings for Applications in Corrosion and Hydrogen Environment Joining of Additively Manufactured Materials Long term behaviour of polymeric liner materials/coatings in hydrogen service Techniques for High Temperature Ultrasonic Inspection of Arc Welding Ultimate Leverage Fund

Project Code: 23066

Industrial Need

Miniturisation in the electronics industry is creating new challenges, and the requirement of using lead-free solder is leading many industry sectors to consider the use of fusion welding electrical interconnections, which are often on a micro scale. A common need for all applications is to have an understanding of the fundamental interactions between the laser beam and the workpiece, and their effects on the resulting quality and properties of the welds. This is required in order to increase industrial confidence in micro laser welding and ensure that factors which influence the resultant in-service performance of the welded joint are understood and controlled.

Objectives

Develop laser welding conditions for thin section lap welding multi-foils of industry relevant Al and Cu alloys, using thin sheets and foils of thicknesses in the range 17μm- 1mm.

Perform metallographic sectioning and optical microscopy of transverse (to the welding direction) weld profiles, to determine layer to layer fusion, porosity, and cracking.

Perform optical evaluation of surface defect (eg melt ejections and fully penetrating blow holes) of the welds produced in Al and Cu alloys.

Characterisation of quality and properties of Cu and Al dissimilar welds (including metallurgical understanding).

Combine the results of this project with previous TWI results to develop a tool or procedure for assisting in equipment and process selection for micro laser processing applications.

Provide on-going support for an Engineering Doctorate (staff development).

Relevant Industry Sectors

Electronics