Optimizing copper laser welding with multi-physics simulations of shaped laser beams

The rise of e-mobility has increased the demand for copper welding, a challenging process due to copper's high reflectivity and thermal conductivity, which cause defects like porosity and spattering. Beam-Shaping enables improvements of the quality of the weld. Multi-Plane Light Conversion technology enables a unique flexibility in the implementation of beam-shaping, leading the need to investigate what shape would give the best process results. We will discuss multi-physics process simulations of different beam-shape, including asymmetric shapes, and how those shapes affect the different parameters of the weld seam such as capillary stability or surface finish.