Laser Welding Solutions for Automotive Cooling Devices

This technical report details the innovative laser welding solutions developed by Feinwerktechnik hago GmbH for producing cooling devices used in battery management controllers (BMC) of electric vehicles. The report outlines the challenges faced in creating a pressure-tight cooling plate from aluminum, measuring 900 x 200 millimeters, which is crucial for effective thermal management. The production team, leveraging BrightLine Weld technology and Multifocus optics from TRUMPF, successfully established a reliable welding process capable of meeting stringent automotive standards. The report describes the initial difficulties encountered with weld seam integrity under pressure tests and how collaborative efforts with TRUMPF led to the development of a stable process for series production. With the completion of a pre-series of approximately 3,000 components, the company anticipates producing over 610,000 cooling devices in the next six years. The report concludes with insights into the potential applications of this technology in future projects.