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Challenges in Copper Laser Welding with a Laser Welding Machine
szhaiwei
2025-10-13
Welding copper using a laser welding machine presents unique challenges due to the material’s physical properties. While copper is widely used in electric vehicles, battery systems, and power electronics, its high thermal conductivity and reflectivity at near-infrared wavelengths make copper laser welding difficult without proper process control.
High Reflectivity at Room Temperature
Copper reflects over 90% of the 1070 nm wavelength commonly used in fiber lasers when cold. This means a significant portion of the laser energy is lost at the start of the weld, increasing the risk of inconsistent melt initiation. To overcome this, modern laser welding machines use high peak power pulses or green lasers (532 nm), which copper absorbs more efficiently.
Rapid Heat Dissipation
Copper’s high thermal conductivity causes heat to spread quickly away from the weld zone. This requires higher energy input and precise beam control to maintain a stable keyhole and sufficient melt pool. Without adequate power density, incomplete penetration or porosity may occur.
Porosity and Spatter Formation
The fast solidification rate of copper can trap gases in the weld, leading to porosity. Unstable keyhole dynamics may also cause spatter, affecting weld quality and requiring post-processing. Using beam oscillation (wobble welding) and optimized shielding gas (typically argon or helium) helps stabilize the process and reduce defects.
Need for Process Monitoring
Due to the sensitivity of copper laser welding, real-time monitoring is recommended. Systems with melt pool sensors or seam tracking can detect inconsistencies early and improve yield, especially in automated production.
Successful copper laser welding depends on matching the laser welding machine capabilities—such as wavelength, power, and beam control—to the application. Haiwei Laser offers cost-effective systems and tailored solutions designed to reliably address the challenges of copper welding, with strong technical support and low maintenance needs. With the right setup and parameter tuning, high-quality, reliable copper welds are achievable in industrial environments.
REPORT