Methods and Systems for Reducing Hazardous Byproduct from Welding Metals Using Lasers
A visible light laser system and operation for welding materials together, without the production of hazardous amounts of metal powders. A blue, blue-green and green laser systems and methods that form welds for aluminum based materials, without the production of hazardous amounts of metal powders. A pore free well using blue, blue-green and green laser automated systems. A blue, blue-green and green laser systems and operations for welding conductive elements, and in particular thin aluminum conductive elements, together for use in energy storage devices, such as battery packs, without the production of hazardous amounts of metal powders.
1 . A method of forming a weld in aluminum based materials, the method comprising:
a. placing a work piece in a laser system; wherein the work piece comprises placing a first piece of aluminum based material in contact with a second piece of aluminum material;
b. directing a blue laser beam at the work piece, whereby a weld is formed between the first piece of aluminum based material and the second piece of aluminum based material; wherein the weld comprises a HAZ and a resolidification zone; and,
c. wherein a microstructure of the aluminum based material, the HAZ and the resolidification zone are identical.
2 . The method of claim 1 , wherein the identical microstructures shows no discernable difference in the weld that would indicate a weakness in the weld.
3 . The method of claim 1 , wherein the identical microstructure comprises crystal growth regions of similar size.
4 . The method of claim 1 , wherein the weld is formed by conduction mode welding.
5 . The method of claim 1 , wherein the first and second pieces have a thickness of from about 10 μm to about 1000 μm.
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21 . The method of claim 1 , wherein the weld that is formed is spatter free.
22 . The method of claim 1 , wherein the laser does not vaporize the work piece.
23 . A method of forming a weld in aluminum based materials, the method comprising:
a. placing a work piece in a laser system; wherein the work piece comprises placing a first piece of aluminum based material in contact with a second piece of aluminum material;
b. directing a blue laser beam at the work piece, whereby a weld is formed between the first piece of aluminum based material and the second piece of aluminum based material; wherein the weld comprises a HAZ and a resolidification zone; and,
c. wherein a range of hardness for the HAZ is within a range of hardness for the aluminum based material.
24 . The method of claim 23 , wherein the range of hardness for the resolidification zone is within a range of hardness for the aluminum based material.
25 . The method of claim 23 , wherein a microstructure of the aluminum based material, the HAZ and the resolidification zone are identical.
26 . The method of claim 25 , wherein the identical microstructures show no discernable difference in the weld that would indicate a weakness in the weld.
27 . The method of claim 26 , wherein the identical microstructures shows no discernable difference in the weld that would indicate a weakness in the weld.
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29 . The method of claim 23 , wherein the weld is formed by conduction mode welding.
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33 . The method of claim 23 , wherein the first piece is an aluminum alloy, having from about 10 to about 95 weight percent aluminum.
34 . The method of claim 23 , wherein the laser beam is directed to the work piece as a focused spot having power density is less than 2000 kW/cm 2 .
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37 . The method of claim 23 , wherein the laser beam is directed to the work piece as a focused spot having power density is greater than 100 kW/cm 2 .
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42 . The method of claim 23 , wherein the laser beam has a power in the range of about 150 W to about 1,500 W.
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47 . The method of claim 23 , wherein the laser does not vaporize the workpiece.
48 . A method of forming a weld in aluminum based materials, the method comprising:
a. placing a work piece in a laser system; wherein the work piece comprises placing a first piece of aluminum based material in contact with a second piece of aluminum material;
b. directing a blue laser beam at the work piece, whereby a weld is formed between the first piece of aluminum based material and the second piece of aluminum based material; wherein the weld comprises a HAZ and a resolidification zone;
c. wherein a range of hardness for the resolidification zone is within a range of hardness for the cooper based material; and,
d. wherein a microstructure of the aluminum based material, the HAZ and the resolidification zone are identical.
49 . The method of claim 48 , wherein the identical microstructures show no discernable difference in the weld that would indicate a weakness in the weld.
50 . The method of claim 48 , wherein the identical microstructures shows no discernable difference in the weld that would indicate a weakness in the weld.
51 . The method of claim 48 , wherein the identical microstructure comprises crystal growth regions of similar size.
52 . The method of claim 48 , wherein the weld is formed by conduction mode welding.
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