Laser Welding Optimization for E-Mobility Applications

This technical report outlines the collaborative research between the Fraunhofer Institute for Laser Technology ILT and TRUMPF focused on optimizing laser welding processes for e-mobility applications. The report details the use of high-precision green laser light for welding copper connections, a critical component in electric vehicles. The research involves a series of experiments conducted at the German Electron Synchrotron DESY, where high-brilliance X-ray light is utilized to observe the laser welding process in real-time. The document describes the meticulous two-year preparation leading up to three days of intensive laboratory work, where various parameters affecting welding quality are analyzed. The goal is to achieve optimal welding speed and accuracy while ensuring the integrity of the ceramic substrates used in high-voltage environments. The findings from these experiments are expected to significantly enhance the efficiency of laser welding processes in the automotive industry, particularly for performance electronics in electric cars.