Flexible and efficient laser remote welding of ultra-thin metal foils

This paper discusses investigations regarding flexible and efficient strategies of laser remote welding of ultra-thin metal foils (≤50 μm) which are applied in the fields of electronics, packaging, and construction. A single-mode fiber laser was used, equipped with a scanner head and diverse objectives. Thus, different optical settings and material thicknesses could be tested and compared with regard to process stability, reliability, and efficiency. The long-term stability of the optical setting was determined related to focus shift and beam shape in the working plane. The specimens were analyzed with methods of micro-sections, microhardness, and tensile strength tests. In this way, it could be shown that laser remote welding of ultra-thin metal foils is a well-suited modern technology which is able to substitute former slower or inflexible techniques, respectively, compound materials with a high in-house production depth.