IMA AUTOMATION Atop and Politecnico di Milano for an innovative article on laser welding solutions

IMA AUTOMATION is honoured to present a groundbreaking academic paper that sheds light on laser welding techniques used in the production of Cu spiral windings for electric drives, in collaboration with the Department of Mechanical Engineering at the Politecnico di Milano.

Laser welding is the industrially accepted method for the joining of Cu hairpin windings in the production of electric drives. High brilliance laser beams are scanned over the bare ends of the Cu wires producing a rapid connection through deep penetration remote welding. Despite being an accepted manufacturing method, laser welding of Cu hairpins still requires detailed studies concerning manufacturing productivity and quality. As the availability of novel laser sources with higher power levels, new wavelengths, and beam shaping capabilities increase, the need for benchmarking studies emerges.

In this study titled “Comprehensive benchmarking of laser welding technologies including novel beam shapes and wavelengths for e-drive copper hairpins”, the collaborative effort between IMA AUTOMATION Atop and the Politecnico di Milano's Department of Mechanical Engineering involved a comprehensive comparison of six distinct laser welding systems employed in the welding of Cu hairpins intended for automotive traction applications.

These cutting-edge laser welding systems presented power levels from 3 to 6 kW, with wavelengths from near infrared (NIR) to visible, including in source dynamic beam shaping. Additionally, the weld bead formation was observed through high-speed imaging. The results showed advantages of each of the employed system while the laser systems providing the highest irradiance profile produced the fastest weld with more elevated mechanical strength independently from the wavelength.

The evaluation of the welding processes encompassed an exhaustive analysis of weld geometry, internal defects, and most significantly, mechanical strength. The results showed advantages of each of the employed system while the laser systems providing the highest irradiance profile produced the fastest weld with more elevated mechanical strength independently from the wavelength.

This innovative research, a testament to the fruitful collaboration between IMA AUTOMATION Atop and the Politecnico di Milano's Department of Mechanical Engineering, not only advances our understanding of laser welding techniques but also lays the groundwork for enhanced productivity and quality in the production of Cu hairpin windings destined for automotive traction.

For more details on this significant research study and its implications for the manufacturing industry, you can access the full article here.