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In the recent years, laser beam welding has become an established joining process, especially for components in the electrical powertrain (copper applications). However, laser beam welding of copper is generally considered to be difficult, particularly due to its high heat conductivity and due to its low absorptivity using laser sources with a wavelength of 1 μm. The resulting welds show numerous weld defects, such as pores and spatters. Using “blue” lasers with a wavelength of 450 nm promises a smoother welding process with less spatters. Therefore, a blue diode laser with increased absorptivity in copper materials was developed by Laserline and used for welding copper. In this contribution, the results of welding copper using blue lasers with respect to the penetration depth and the resulting weld quality are discussed. In addition, investigations by Bosch at the electron-synchrotron DESY with a blue diode laser enabled us to have a look into the material during welding. Consequently, melt pool dynamics and capillary dynamics were analyzed with respect to the formation of weld defects and will be discussed as well. Furthermore, it is demonstrated that it can be beneficial to use a so-called spot-in-spot beam shaping tool to further improve the melt pool dynamics and, therefore, the resulting weld quality.
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