Quality improvement on dissimilar metals fibre laser welded between nickel and copper

<ns3:p>The study investigates the power and wobble diameter quality on the physical and mechanical properties of fibre laser-welded joints of dissimilar metals, specifically nickel and copper. The research aims to provide valuable insights into optimising welding parameters to enhance the performance and reliability of electric vehicle components.Dissimilar welding between nickel and copper has been increasingly applied to electric vehicle components due to the unique properties of the metals when combined. Fibre laser welding, a technology known for its precision and efficiency, is highly suitable for joining dissimilar metals. It offers advantages such as low heat input, minimal distortion, and high beam focus. It is an excellent choice for welding applications that demand high-quality joints with minimal thermal damage. The welding process in this study was conducted with three different power settings: 420 watts, 450 watts, and 480 watts. Three wobble diameters were also tested: 3 mm, 3.2 mm, and 3.4 mm. These variations allowed for a comprehensive analysis of how these parameters influence the ultimate shear strength (USS), ultimate tensile strength (UTS), and hardness of the welded joints.The study found a clear correlation between the welding parameters and the mechanical properties of the joints. Both U.S.S. and UTS increased with higher power settings, with the highest values of USS (56.277 MPa) and UTS (4.079 MPa) at 480 W, indicating stronger welds due to better penetration and fusion. Additionally, smaller wobble diameters led to higher USS (40.229 MPa) and UTS (2.453 MPa), likely due to more concentrated energy input and improved joint formation. Regarding hardness, the highest value (204 HVN) was recorded at 420 W with a wobble diameter of 3.2 mm, suggesting that lower power and smaller wobble diameters contribute to finer microstructures, enhancing joint hardness. Microstructural analysis showed grain refinement in the heat-affected zone and a distinct fusion between nickel and copper in the fusion zone, indicating high-quality welds.The research is limited to specific power and wobble diameter settings, focusing on the properties of nickel and copper fibre-welded joints. Further studies could explore various parameters, including different laser types, welding speeds, and other dissimilar metal combinations. Additionally, long-term performance and durability tests under various environmental conditions would provide a more comprehensive understanding of the welds' suitability for practical applications.The research is limited to specific power and wobble diameter settings, focusing on the properties of fibre laser-welded joints of nickel and copper. Further studies could explore various parameters, including laser types, welding speeds, and other dissimilar metal combinations. Additionally, long-term performance and durability tests under various environmental conditions would provide a more comprehensive understanding of the welds' suitability for practical applications.The study contributes to the growing body of knowledge on fibre laser welding of dissimilar metals, specifically nickel and copper. It provides valuable insights into how power and wobble diameter settings affect the physical and mechanical properties of welded joints. The research provides practical guidance for industries seeking to integrate advanced welding techniques into their production processes, thereby enhancing the quality and performance of their products.</ns3:p>