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Fundamental Study of Micro Welding with Continuous-Wave Laser Sources

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.


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


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