Effects of Different Oscillation Modes on AMB Laser Welding of Multi-layer Copper Foils and Nickel-plated Copper Sheets at High Welding Speed

GUO Junzhuo; LI Liqun; LI Haoyue; GONG Jianfeng; XIA Hongbo; LI Zhongbing; ZENG Xiangbing; ZHANG Chuanjian; CHEN Chengbing; SUN Yikun; ZHANG Daoyang; YUAN Dingkai; ZHAO Li&#x02032;na

doi:10.3969/j.issn.1674-6457.2026.06.002

PDF(24836 KB)

Journal of Netshape Forming Engineering ›› 2026, Vol. 18 ›› Issue (6) : 16-27. DOI: 10.3969/j.issn.1674-6457.2026.06.002

Joining of New Materials and Dissimilar Materials

Effects of Different Oscillation Modes on AMB Laser Welding of Multi-layer Copper Foils and Nickel-plated Copper Sheets at High Welding Speed

GUO Junzhuo^1,2, LI Liqun^1,2, LI Haoyue^1,2,*, GONG Jianfeng², XIA Hongbo^1,2, LI Zhongbing³, ZENG Xiangbing³, ZHANG Chuanjian³, CHEN Chengbing³, SUN Yikun³, ZHANG Daoyang³, YUAN Dingkai⁴, ZHAO Li′na⁴

Author information +

History +

Abstract

The work aims to investigate the effect laws and mechanisms of three laser oscillation modes (linear, circular, and 8-shaped) on the weld quality of AMB (Adjustable Mode Beam) laser welding at a high scanning speed of 300 mm/s, so as to provide a basis for process optimization. An AMB laser was used to perform stack welding experiments on a 32-layer copper foil with a thickness of 6 μm and a 0.2 mm-thick nickel-plated copper sheet (with a nickel plating layer of 0.1 μm). Metallographic analysis was conducted to measure penetration depth, weld width, and porosity. High-speed camera and spatter collection paper were used to observe spatter behavior. Weld resistance and shear force were tested, and their fluctuations were calculated to evaluate process applicability. Energy distribution was calculated with MATLAB to reveal the effect mechanism of different oscillation modes on weld formation and quality. The linear oscillation mode reduced porosity by 1.9% compared to non-oscillation mode and produced fewer spatters with smaller sizes, reduced penetration depth fluctuation by 4.1%, achieved the lowest resistance and the highest shear force, and showed the smallest performance fluctuation. The circular and 8-shaped oscillation modes both increased porosity defects, generated large spatters, increased resistance, decreased shear force, and significantly increased fluctuation. Energy distribution calculation showed that the latter two modes had local energy accumulation and uneven distribution due to track overlap or crossing. The linear oscillation had uniform energy distribution. At high welding speed, the mismatch between oscillation frequency and welding speed prevents non-linear oscillation cycles from interacting effectively, causing local energy accumulation and exacerbating weld defects. The linear oscillation, with its simple path and no overlap or crossing, provides uniform energy distribution and achieves the best welding quality and process repeatability. Therefore, the linear oscillation is a better choice than the other oscillation modes at high welding speed.

Key words

AMB laser welding / laser oscillation mode / multi-layer copper foils / high welding speed

Cite this article

EndNote

Ris (Procite)

Bibtex

Download Citations

GUO Junzhuo, LI Liqun, LI Haoyue, GONG Jianfeng, XIA Hongbo, LI Zhongbing, ZENG Xiangbing, ZHANG Chuanjian, CHEN Chengbing, SUN Yikun, ZHANG Daoyang, YUAN Dingkai, ZHAO Li′na. Effects of Different Oscillation Modes on AMB Laser Welding of Multi-layer Copper Foils and Nickel-plated Copper Sheets at High Welding Speed[J]. Journal of Netshape Forming Engineering. 2026, 18(6): 16-27 https://doi.org/10.3969/j.issn.1674-6457.2026.06.002

References

[1] TANG J Y, LIANG Q, HE L, et al.An Environmentally Friendly and Scalable Manufacturing Route to the High Performance Composite Polymer Electrolytes for Lithium-Metal Batteries[J]. Journal of Manufacturing Processes, 2024, 120: 404-413.
[2] ANK M, SOMMER A, ABO GAMRA K, et al.Lithium-Ion Cells in Automotive Applications: Tesla 4680 Cylindrical Cell Teardown and Characterization[J]. Journal of the Electrochemical Society, 2023, 170(12): 120536.
[3] 蔡佳思, 凌畅, 孔英杰, 等. 基于RSM的6061-T6铝合金激光深熔焊工艺参数优化[J]. 精密成形工程, 2025, 17(5): 1-11.
CAI J S, LING C, KONG Y J, et al.Optimization of Laser Deep Penetration Welding Parameters of 6061-T6 Aluminum Alloy Based on RSM[J]. Journal of Netshape Forming Engineering, 2025, 17(5): 1-11.
[4] 李景轩, 毛育青, 徐良, 等. TA17钛合金/钒/321不锈钢双道激光焊接头显微组织及力学性能[J]. 精密成形工程, 2026, 18(2): 134-144.
LI J X, MAO Y Q, XU L, et al.Microstructure and Mechanical Properties of Double-Pass Laser Welded TA17 Titanium Alloy/Vanadium/321 Stainless Steel Dissimilar Joints[J]. Journal of Netshape Forming Engineering, 2026, 18(2): 134-144.
[5] 刘品潇, 刘昊男, 刘振阳, 等. Q235钢激光成形工艺及焊缝质量研究[J]. 精密成形工程, 2026, 18(1): 149-159.
LIU P X, LIU H N, LIU Z Y, et al.Laser Forming Process and Weld Quality of Q235 Steel[J]. Journal of Netshape Forming Engineering, 2026, 18(1): 149-159.
[6] HEINEN P, HAEUSLER A, MEHLMANN B, et al.Laser Beam Microwelding of Lithium-ion Battery Cells with Copper Connectors for Electrical Connections in Energy Storage Devices[J]. Review of Education, Pedagogy, and Cultural Studies, 1995, 17(1): 1-6.
[7] TRINH L, LEE D.A Study on Laser Welding for Dissimilar Metals of Aluminum and Copper Using Pulsed Fiber Laser[J]. International Journal of Precision Engineering and Manufacturing, 2024, 25(12): 2467-2477.
[8] AUWAL S T, RAMESH S, YUSOF F, et al.A Review on Laser Beam Welding of Copper Alloys[J]. The International Journal of Advanced Manufacturing Technology, 2018, 96(1): 475-490.
[9] HELM J, SCHULZ A, OLOWINSKY A, et al.Laser Welding of Laser-Structured Copper Connectors for Battery Applications and Power Electronics[J]. Welding in the World, 2020, 64(4): 611-622.
[10] MIYAGI M, ZHANG X D.Investigation of Laser Welding Phenomena of Pure Copper by X-Ray Observation System[J]. Journal of Laser Applications, 2015, 27(4): 042005.
[11] YUAN X L, LIU X, ZUO J.The Development of New Energy Vehicles for a Sustainable Future: A Review[J]. Renewable and Sustainable Energy Reviews, 2015, 42: 298-305.
[12] ENGELHARDT T, BRANDNER M, WEBER R, et al.Influence of Welding Parameters and Stack Configuration on Pore Formation of Laser Welded Aluminum Foil Stacks[C]// Proceeding of lasers in manufacuturing. Center München, Germany: International Congress Centre Munich, 2015.
[13] KAMAT S, CAI W, RINKER T J, et al.A Novel Integrated Process-Performance Model for Laser Welding of Multi-Layer Battery Foils and Tabs[J]. Journal of Materials Processing Technology, 2023, 320: 118121.
[14] OLOWINSKY A, SPURK C, HELM J, et al.Laser-Based Joining of Electrode Stacks for Automated Large-Scale Production of Li-Ion Battery Cells[J]. Energy Technology, 2023, 11(5): 2200770.
[15] TAKENAKA K, SATO Y, FUJIO S, et al.Comparison of Melting Efficiency between Blue, Green, and IR Lasers in Pure Copper Welding[J]. Journal of Laser Applications, 2023, 35(4): 042012.
[16] SCHEDEWY R, BEYER E, BRENNER B, et al.Prospects of Welding Foils with Solid State Laser for Lithium-Ion Batteries[J]. Optics & Laser Technology, 2011 (10): 23-27.
[17] GALBUSERA F, CAPRIO L, PREVITALI B, et al.The Influence of Novel Beam Shapes on Melt Pool Shape and Mechanical Properties of LPBF Produced Al-Alloy[J]. Journal of Manufacturing Processes, 2023, 85: 1024-1036.
[18] GALBUSERA F, CAPRIO L, PREVITALI B, et al.Analytical Modeling and Characterization of Ring Beam Profiles for High-Power Lasers Used in Industrial Manufacturing[J]. Journal of Manufacturing Processes, 2024, 117: 387-404.
[19] SUN T Z, MOHAN A, LIU C H, et al.The Impact of Adjustable-Ring-Mode (ARM) Laser Beam on the Microstructure and Mechanical Performance in Remote Laser Welding of High Strength Aluminium Alloys[J]. Journal of Materials Research and Technology, 2022, 21: 2247-2261.
[20] WANG L, GAO X D, KONG F R.Keyhole Dynamic Status and Spatter Behavior during Welding of Stainless Steel with Adjustable-Ring Mode Laser Beam[J]. Journal of Manufacturing Processes, 2022, 74: 201-219.
[21] 宫照亮, 蒋平, 施建宏, 等. 动力电池1060铝合金薄板可调环形光斑激光搭接焊工艺优化[J]. 焊接学报, 2023, 44(11): 67-79.
GONG Z L, JIANG P, SHI J H, et al.Optimization of Laser Lap Welding Process of Power Battery 1060 Aluminum Alloy Sheet with Adjustable Ring Spot[J]. Transactions of the China Welding Institution, 2023, 44(11): 67-79.
[22] MAINA M R, OKAMOTO Y, OKADA A, et al.High Surface Quality Welding of Aluminum Using Adjustable Ring-Mode Fiber Laser[J]. Journal of Materials Processing Technology, 2018, 258: 180-188.
[23] XU H, WANG R, HAN L J, et al.Enhancing Shear Performance of Heat-Treatment-Free Die-Casting Aluminum Alloy Joints with Laser Beam Oscillation Welding: An Examination of Microstructure and Mechanisms[J]. Materials Letters, 2025, 384: 138094.
[24] WANG L, GAO M, ZHANG C, et al.Effect of Beam Oscillating Pattern on Weld Characterization of Laser Welding of AA6061-T6 Aluminum Alloy[J]. Materials & Design, 2016, 108: 707-717.
[25] YANG H W, CHEN J, ZHAO X Y, et al.Effect of Laser Beam Wobbling and Welding Speed in X80 Steel Wire-Fed Laser Root Welds[J]. Journal of Materials Processing Technology, 2024, 327: 118383.
[26] AVCI U, FRANCIOSA P.Effect of Laser Power on Weld Microstructure of AA6082 Sheets Remote Laser Welded by Circular Beam Wobbling[J]. Welding in the World, 2024, 68(10): 2761-2777.
[27] GUO J Z, LI H Y, LI L Q, et al.The Effect of Preload Modulation on Laser Weld Quality of Multilayer Copper Micro-Foils and Anode Disk[J]. Optics & Laser Technology, 2025, 192: 113998.
[28] 王智海, 陈力. 动力锂电池极耳激光焊接成形和组织性能研究[J]. 电池工业, 2022, 26(6): 286-291.
WANG Z H, CHEN L.Research on Laser Welding Forming and Microstructure Properties of Power Lithium Battery Tabs[J]. Chinese Battery Industry, 2022, 26(6): 286-291.
[29] KUMAR N, PAMARTHI V V, DAS A.Investigating Laser and Ultrasonic Welding of Pouch Cell Multi-Foil Current Collectors for Electric Vehicle Battery Fabrication[J]. The International Journal of Advanced Manufacturing Technology, 2024, 134(5): 2497-2511.
[30] HORNÍK P, ŠEBESTOVÁ H, NOVOTNÝ J, et al. Laser Beam Oscillation Strategy for Weld Geometry Variation[J]. Journal of Manufacturing Processes, 2022, 84: 216-222.
[31] GONG J F, LI L Q, MENG S H, et al.Study on Stability and Microstructure Properties of Oscillating Laser Welded 5A06 Alloy with Narrow Gap[J]. Optics & Laser Technology, 2022, 155: 108360.
[32] GONG J F, PENG G C, LI L Q, et al.Effect of Plasma Plume Produced by Vacuum Laser Welding on Energy Transmission[J]. Optics & Laser Technology, 2021, 136: 106744.

Funding

The Major Science and Technology Research Project of Anhui Province (2023z020003); National Natural Science Foundation of China (52505366); China Postdoctoral Science Foundation (2024M764175)