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Welding Thick Copper Bus Bars for High Current Applications

Dynamic Beam Laser welding 4.6mm of copper
Thick Copper Welding

As the battery industry continues to evolve and expand, the demand for batteries capable of handling higher power inputs has surged. This is particularly evident in sectors such as E-planes, E- boats and renewable energy storage. A critical component in achieving these high-power requirements is the use of bus bars, which are essentially conductive bars used to distribute power across different sections of a battery or between batteries.

The Shift to Higher Voltage and Thicker Bus Bars

To accommodate the need for higher power input, there's been a marked shift towards managing higher voltages within battery systems. This adjustment necessitates the use of thicker bus bars. Thicker bus bars are instrumental in handling the increased electrical load without overheating or losing efficiency. Copper, known for its excellent conductivity and durability, is the material of choice for these bus bars. However, welding thick copper bus bars, especially those above 4 mm in thickness, presents significant challenges.


Challenges in Welding Thick Copper

Welding thick copper is a complex task, primarily because most conventional lasers struggle to achieve a robust process that meets the necessary quality standards for such materials. The challenges are manifold:

  • High Thermal Conductivity: Copper's high thermal conductivity complicates the welding process by dissipating heat rapidly, making it difficult to maintain the high temperatures needed for keyhole weld.

  • Thickness Challenges: When the copper's thickness exceeds 4mm, these challenges become even more pronounced, making it difficult to achieve consistent and high-quality welds and requiring higher power levels.

  • Blowholes & Porosity: porosity in common to find in copper welds. Blowholes are a specific type of porosity that occurs when larger gas pockets get trapped in the weld. These defects are particularly problematic in thick copper welding because of the metal's high thermal conductivity and the large volume of material. Managing the welding atmosphere and parameters is crucial to minimize the risk of blowholes.


A Breakthrough with Civan's Dynamic Beam Laser

Despite these obstacles, recent advancements have paved the way for significant improvements in welding thick copper bus bars. A notable breakthrough has been achieved by Civan's Dynamic Beam Laser technology. This innovative approach has demonstrated the capability to weld copper with a thickness of 4.6 mm, maintaining high quality throughout the process.


Civan's Dynamic Beam Laser technology stands out because it offers a large parameter window, allowing for greater flexibility and control over the welding process. This adaptability is crucial for dealing with copper's inherent challenges. By precisely controlling the laser's parameters, Civan's technology can maintain the necessary Keyhole and melt pool dynamics, achieving strong and reliable welds even in thick copper bus bars.

Dynamic Beam Laser weding of thick copper
Copper welding analysis

Dynamic Beam Laser high weld quality
Copper welding cross sections


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