Laser Welding Optimization for E-Mobility Applications

This technical report outlines a collaborative study between the Fraunhofer Institute for Laser Technology ILT and TRUMPF focused on optimizing laser welding processes for e-mobility applications. The objective is to enhance the high-precision, high-speed welding of copper connections using green laser light. The research involves a series of experiments utilizing advanced X-ray light at the German Electron Synchrotron DESY in Hamburg, a facility equipped with the necessary particle accelerators. The teams aim to investigate the welding of metal-ceramic substrates (MCS), which are critical for connecting electronic components in high-voltage environments, such as electric vehicles. Over two years of preparation culminated in three intensive experimental days, during which various laser parameters were tested to achieve optimal welding speed and accuracy. The report details the methodology, challenges, and the anticipated impact of the findings on the automotive industry, particularly in improving the efficiency of laser welding processes.