Laser Processing Unit for Highly Reflective Materials (GreenPls)

 

The automotive industry is undergoing a transformation. High CO2 emissions make the development of alternative drive concepts necessary and electric vehicles currently represent the most promising solution. One of the most relevant joining technologies for electromobility components is laser beam welding. High precision, contactless welding joints and flexible process design options make it possible to meet high quality requirements. Due to their good electrical and thermal conductivities, materials such as copper and aluminium are commonly used.
A solution for joining these materials is the use of green laser radiation, which is absorbed more strongly in copper by a factor of about 5 compared to lasers in the infrared range.

In order to improve the performance of the green laser for the production of electric vehicle components, a comprehensive concept for a modular laser processing unit with green laser radiation is being developed and compared with conventional infrared lasers as part of the "GreenPls" research project. For this purpose, work is being carried out in the research fields of process optimisation and monitoring, device and safety technology as well as a system layout adapted to the application field of electric vehicle components. At the WZL, the research work is practically implemented with the infrastructure of the ramp-up factory and tested under real conditions: Fixture and prototype components are manufactured using laser cutting and additive manufacturing. A safety concept and battery prototypes are developed, tested and assembled in the laser welding cell. A high degree of maturity of the research results is to be achieved through the full consideration of process development up to a complete plant layout, which ensures a rapid industrial use of the research content.