Pore formation and melt pool analysis of laser welded Al-Cu joints using synchrotron radiation

Known as challenging material combination, the welding of aluminium and copper, both with strongly different thermophysical properties, causes joining failures such pores, cracks or intermetallic phases in solidified area. To investigate mixing materials occurrence laser process is observed synchrotron radiation which visualizes phase boundaries between solid, liquid gaseous phases. This allows visualization pore formation density differences inside melt pool. In this investigation, front bottom keyhole observed. The movement bubbles pool can be tracked until solidification at transition. Regarding intermixing materials, high-speed images show a fluctuating copper flow towards over entire depth. By understanding mechanisms, compensatory measures for an improved developed to enable usability connections, example electromobility applications.