New Achievement: Aluminum Busbar / Copper Braid
Our Innovations & Prototypes Department has recently carried out new aluminum-to-copper assemblies using laser welding technology. Aluminum is increasingly being used as a substitute for copper, thanks to its excellent recyclability and lightweight properties.
Depending on design constraints, two different laser welding techniques can be applied:
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Edge-to-edge welding: ideal when compactness is required.
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Overlap welding: recommended for thin sections (0.1 to 3 mm).
👉 Example shown:
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Edge-to-edge assembly of a 5 mm aluminum busbar welded to a 70 mm² copper braid.
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Overlap welding of a 1.5 mm aluminum busbar on the same copper braid section.
Key Advantages of Laser Welding
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Reliable joining of dissimilar materials (Al/Cu).
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Low contact resistance, critical for high-current applications.
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High precision and reproducibility, suitable for industrial-scale production.
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Minimal heat-affected zone (HAZ), preserving material properties.
Meeting New Industrial Challenges
These developments directly address the needs of industries where high-current conduction is essential. At TECHNAX, numerous applications have already been achieved in:
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E-mobility
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Stationary energy storage
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Power electronics
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Railway systems
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Aerospace and aeronautics
➡️ With these achievements, TECHNAX continues to provide innovative laser solutions that support the evolution of tomorrow’s energy and mobility systems.