Robust laser micro welding of aluminum and copper for vehicle electrical systems

An upgraded double-sided cooled power module is presented which overcomes the current disadvantages of conventional modules considering power density and efficiency. Besides a detailed description of the new assembly, in this context an introduction is given into joining processes by laser micro welding. The laser is a promising tool for highly automatable and most efficient packaging technology. This paper describes methods to increase the process robustness of hard to weld electronic materials which can be effectuated by pulse shaping and adapted laser wavelength. Moreover the impact of laser processing upon weld deformation is investigated.