Dissimilar Laser Micro-Welding of Nickel Wire to CuSn6 Bronze Terminal

In the present study, the laser welding of wire to
flat geometry for miniature electromechanical hybrid
components has been investigated. Considering the
geometry of parts to be welded and also requirement of
mechanical properties, spatial modulation of the laser beam
was needed to be implemented to achieve a sound joint.
Tensile-shear test and optical microscopy were employed
to represent the mechanical properties and melt pool
geometry of the joints. All welds were done by power
modulation of the laser beam to better control the energy
input at several feed rates and three different beam trajectories.
Results showed that the shear load of the joint
could be controlled by feed rate and the trajectory of the
laser beam. Considering the material combination of the
study that were nickel and CuSn6 bronze, which represented
solubility in solid state, a joint stronger than base
wire metal was achieved by defining a proper spatial
modulation and feed rate of the laser beam.