Investigation on LASER welding of wrought aluminum sheets to high pressure die cast and additive manufactured components

Laser welding of aluminum alloys coming from different production processes has currently gained a strong interest especially in the production of cases for e-mobility batteries. In particular, wrought thin sheets made in Al 5xxx or 6xxx alloys are often welded on AlSi high pressure die cast or additive manufactured components with the goal to manufacture enclosures that guarantee the right trade-off between weight, mechanical resistance and heat management. The present paper investigates the role of process parameters in lap welding of Al 5xxx wrought sheets on AlSi high pressure die cast and additive manufactured plates. The main focus is to relate process parameters and welding strategy to the formation of porosities and to the overall quality of the joint.