Joining thin copper wire and copper busbar by remote laser welding for electric motor assembly: Impact of welding parameters and pre-welding surface treatment

Abstract

This article explores the application of remote laser welding for joining thin copper wire and copper sheet in a T-joint configuration for rapid assembly of busbar and winding wire of electric motors. The method utilises wire itself as filler material, ensuring effective gap filling between the wire and busbar, and achieving a robust electrical and mechanical connection throughout the entire busbar thickness. Notably, the approach exhibits a remarkable mechanical load capacity of 221 N, equivalent to 92.5% of the strength of enamelled wire. Furthermore, results indicate comparable mechanical, electrical, and thermal performance despite varied pre-welding surface treatments on the copper busbar, demonstrating the high tolerance of the proposed welding approach against pre-welding surface conditions and hence the high practical applicability.