Tensile strength of specimens manufactured using laser wire bonding

Tensegrity structures are used for lightweight design. They consist of several elements that bear compressive or tensile loads. Ropes and cables are usually used to bear occurring tensile loads, but wires can also be used. The process of laser wire bonding was investigated in a previous study using a coaxial deposition welding head and a continuous wave laser beam source. Wires made of G4Si1 with a diameter of 1 mm were bonded to a mild steel substrate, and a process window for a laser wire bonding process with sufficient bonding quality was determined. Based on these findings, tensile tests were carried out to investigate the influence of the process parameters (stickout, laser power, wire feed rate, and bonding processing time) and the resulting geometry of the bonding zone on the maximum force. As a reference, tensile tests were carried out with the wire material in its original state.