Evaluating the Mechanical Properties and Weldability of Pure Copper Foils: Insights from Fluid Mechanics in Blue Diode Laser Welding

Qiang Cau^*
*Correspondence: Qiang Cau, Department of Engineering Design, Western Michigan University, Kalamazoo, USA, Email:

Introduction

Pure copper, with its excellent electrical and thermal conductivity, is an essential material in a variety of industrial applications, including electronics, power transmission, and heat exchangers. However, welding pure copper presents unique challenges due to its high thermal conductivity, low melting point, and susceptibility to distortion during welding. This is particularly true when working with thin copper foils, which are commonly used in highprecision applications such as microelectronics, flexible circuits, and battery technology. To address these challenges, blue diode laser welding has emerged as an effective method for joining pure copper foils. This welding technique, which uses a high-intensity blue laser, offers precise control over the welding process, reducing heat-affected zones and minimizing material distortion. To optimize the welding of copper foils and improve mechanical properties, it is essential to consider not only the thermal dynamics of the process but also the underlying fluid mechanics that govern the molten pool behavior, material flow, and solidification. In this article, we will explore the mechanical properties and weldability of pure copper foils, focusing on how fluid mechanics can offer insights into the blue diode laser welding process. Understanding the fluid flow and heat transfer mechanisms that occur during welding is crucial for achieving optimal weld quality, minimizing defects, and improving the overall performance of the welded joints [1-3].

Description

Fluid mechanics plays a crucial role in understanding and optimizing the welding process, especially in terms of how the molten pool behaves during laser welding. The welding process involves melting a portion of the copper foil to form a molten pool, which solidifies as the heat source moves along the joint. The size, shape, and flow of the molten pool are essential for creating high-quality welds. A stable and well-formed molten pool ensures uniform heat distribution, prevents defects such as porosity or cracks, and allows for efficient heat dissipation. In blue diode laser welding, the high-intensity laser beam rapidly melts the copper surface, creating a localized molten pool. The size of the molten pool is influenced by the laser power, scanning speed, and material properties. The fluid flow within the molten pool is governed by convection, surface tension forces, and heat gradients. The interaction between these forces determines the flow patterns within the pool, which can affect the weld quality. One important phenomenon within the molten pool is Marangoni flow, which arises due to surface tension gradients caused by temperature differences. In copper welding, the intense heat generated by the laser causes temperature variations within the molten pool. Areas of the pool that are hotter tend to have lower surface tension, while cooler regions exhibit higher surface tension. This gradient causes the molten material to flow from hot areas to cooler areas, which can lead to the formation of more stable and uniform welds. However, if the Marangoni flow is not properly managed, it can result in defects such as excessive spatter or irregular weld profiles. Understanding and controlling Marangoni flow is vital for improving the weldability of copper foils, particularly when using blue diode lasers that generate high-intensity heat in a localized region [4,5].

Conclusion

Blue diode laser welding offers several advantages for joining pure copper foils, particularly in applications that require high precision and minimal thermal distortion. However, to fully optimize the welding process and achieve high-quality welds, it is essential to understand the fluid mechanics at play within the molten pool. Key fluid dynamics phenomena, such as Marangoni flow, heat transfer, cooling rates, and material flow, significantly impact the mechanical properties and weldability of the copper foils. By controlling these fluid mechanics factors, it is possible to minimize defects such as porosity and cracking, while enhancing the overall strength, ductility, and fatigue resistance of the welds. Blue diode laser welding, when coupled with a deep understanding of fluid mechanics, holds great promise for applications in microelectronics, flexible circuits, and other industries requiring highperformance copper joints.

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