Blue Light Composite Single Wobble Laser Welding Head 70% Absorption Rate for Copper

The HW-B is a blue light composite single wobble laser welding head that combines a 450nm blue laser with a fiber laser source in one compact welding head. Blue light is absorbed far more efficiently by copper and aluminium than the conventional 1064nm infrared (red light) laser, so the same weld depth can be reached with a considerably lower laser power.

Copper and aluminium are highly reflective to infrared laser light at room temperature, which forces machine builders to install oversized laser sources and complex process controls. When welding with a 450nm blue laser, the absorption rate on copper rises to approximately 70 percent, and the absorption stays high even in the molten pool. The result is a stable keyhole, a wide process window and a welding result that does not depend on a perfectly prepared surface.

• Approximately 70 percent absorption rate on copper and other highly reflective metals, compared with a few percent for the same material under a 1064nm red light laser.
• Greatly reduced laser power requirement and therefore a lower equipment cost, lower power consumption and a smaller chiller footprint for the same penetration depth.
• Spatter free welding process that keeps the workpiece, the optics and the working area clean and removes the need for post weld cleaning.
• High quality, stable welding with repeatable penetration from part to part, even on long production runs.
• Smooth weld seam appearance that requires little or no grinding before painting or inspection.
• Single sided welding with double sided forming on thin to medium sheet, so one pass produces a finished seam on both faces of the joint.
• Better weld quality and wider gap tolerance, the single wobble scanning pattern bridges joint gaps, fit up errors and slight edge misalignment far better than a static spot.

The wobble module oscillates the focused beam in a controlled pattern while the head travels along the seam. This spreads the energy over a wider area, slows the cooling rate of the melt pool and lets dissolved gas escape before solidification. Combined with the high blue light absorption, the process delivers a smooth, spatter free bead with a fine grain structure and a consistent penetration profile from start to end of the seam.

• Copper busbar, copper foil and copper connector welding in battery packs and energy storage modules
• Aluminium alloy housing, heat sink and structural part welding
• New energy vehicle motor hairpin, stator and power electronics joining
• Thin metal cabinets, doors and panels that need a smooth paint ready seam
• Precision hardware, electronics and medical device metal assemblies

Every head passes a full optical path inspection, a laser power throughput test and a continuous 8 hour burn in run before shipment. Welded sample coupons in copper and aluminium are supplied with each order so the customer can verify penetration, spatter level and seam appearance against the agreed standard.

HanWei Laser Equipment Co., Ltd is a manufacturer of fiber, diode, hybrid and blue laser welding systems for battery, new energy, aerospace, jewellery, metal processing and medical industries. Our heads and machines are exported worldwide and supported by local distributors in Europe, North America, Asia and the Middle East.