Towards industrial ultrafast laser microwelding: SiO₂ and BK7 to aluminum alloy

We report systematic analysis and comparison of ps-laser microwelding of industry relevant Al6082 parts to SiO₂ and BK7. Parameter mapping of pulse energy and focal depth on the weld strength is presented. The welding process was found to be strongly dependent on the focal plane but has a large tolerance to variation in pulse energy. Accelerated lifetime tests by thermal cycling from -50° to +90°C are presented. Welds in Al6082-BK7 parts survive over the full temperature range where the ratio of thermal expansion coefficients is 3.4:1. Welds in Al6082-SiO₂ parts (ratio 47.1:1) survive only a limited temperature range.