Professional and efficient laser welding technology is becoming a new choice for connecting conductive components such as copper lugs.
In power equipment, new energy products, and various electrical systems, copper lugs are key connecting components for wires and cables, and their welding quality directly affects the conductivity and reliability of the equipment. Traditional welding methods suffer from drawbacks such as large heat-affected zones, significant deformation, and unstable connection resistance.
Guangdong Fly Laser, with years of accumulated laser technology experience, provides efficient and high-precision solutions for copper lug welding.
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Copper Lug Welding
01 Copper Welding Challenges: From High Reflectivity to High Precision
Copper and copper alloys are the preferred materials for electrical connection components due to their excellent electrical and thermal conductivity, but this characteristic presents challenges for laser welding.
Copper has high reflectivity to most high-power industrial lasers, and coupled with its high thermal conductivity during the welding process, traditional welding methods are prone to problems such as difficult fusion, large deformation, and unstable welding.
Deep copper laser welding technology can help manufacturers create stronger, lighter, and more efficient electrical connection components to meet the needs of a sustainable future.
02 Fly Laser Welding Solutions: Professional Equipment and Technological Advantages
Since its establishment in 2008, Guangdong Feilai Laser has focused on the R&D, production, and sales of laser devices and complete sets of laser processing equipment.
The company boasts a professional management system, R&D system, and technical support system, and has built a global marketing and service network.
For welding highly reflective materials such as copper noses, Feilai Laser offers a variety of solutions:
Annular spot welding uses a single fiber to output two coaxial beams. The power of the central beam and the outer ring beam can be independently adjusted. This achieves greater penetration depth at high speeds while effectively reducing spatter, resulting in a smooth and aesthetically pleasing weld.
Single-mode laser + oscillating welding achieves higher power density through a smaller fiber core diameter. In oscillating mode, the energy distribution is relatively uniform, resulting in a stable keyhole and effectively reducing porosity and spatter caused by unstable energy coupling in copper.
Green laser welding utilizes the fact that copper absorbs green laser light at room temperature much more readily than near-infrared laser light, reducing product deformation and minimizing damage to components around the welding site.
03 Advantages of Laser Welding Applications: High Efficiency, High Precision, Automation
Laser welding of copper lugs offers significant advantages over traditional welding methods:
High Welding Speed: Laser welding is faster than traditional methods, improving production efficiency.
Minor Deformation: Material deformation is minimal during laser welding, reducing post-weld processing.
High Precision: Laser welding achieves high-precision welding, meeting the demands of high-precision products.
Automated Production: Laser welding enables automation, improving production efficiency and reducing costs.
Non-Contact Processing: The laser is a wear-free, non-contact tool, preventing component contamination and damage.
04 Industry Application Prospects: From Power Equipment to New Energy Vehicles
With the rapid development of the new energy vehicle and electronics industries, copper and copper alloys play a crucial role in products such as motors, sensors, power generation and transmission equipment, and circuit boards, leading to a growing demand for connections between copper components.
Typical applications in electric vehicles include inverter welding and battery pack busbar connections.
In power equipment, copper lugs are crucial components for conductor connections, and their welding quality directly impacts the efficiency and safety of power transmission.
In the field of electronic components, laser welding enables micro-welding of precision components, particularly suitable for welding highly reflective materials and dissimilar metals.
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Fly Laser's deep copper welding technology can achieve welds up to 7 mm deep, boasting excellent electrical performance and minimal porosity. For companies engaged in the production of power equipment, new energy products, and various electrical systems, choosing a professional laser welding solution is undoubtedly a wise move to enhance product competitiveness.
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