Effect of different laser beam oscillating strategies on dissimilar welding of Al to Hilumin for EV applications

Abstract

This study utilized the TRUMPF TruFibre 6000 P laser system, which enables beam shaping, to research the effects of different laser beam oscillation strategies on the dissimilar welding of AA1050 aluminum alloy and Hilumin plates. Under different welding speeds and ring power parameters, it evaluated three oscillation strategies: circular oscillation, infinite oscillation, and zigzag oscillation. First, through plate welding tests, the process windows for different welding strategies were determined. Then, for the successful experimental data, metallographic analysis and lap shear tensile tests were conducted. The results show that the circular oscillation strategy has a wider process window; the infinite oscillation strategy failed to realize effective fusion within the tested parameter range; and the zigzag oscillation strategy requires higher ring power to achieve good mechanical properties. These findings provide reference for dissimilar metal welding, indicating that through proper control of heat input and oscillation strategies, the mechanical joint performance in EV battery applications can be improved.