This paper presents the results of laser joined copper-aluminum lap shear samples without filler materials using an IPG 500W SM fiber laser. The length of the processed laser joint was about 20 mm and the width was about 200 μm. Laser-joined samples were tested under tensile loading to determine joint strengths. In addition, finite element analysis (FEA) was conducted to understand the stress distribution within the bond area under such loading. The FEA model provides a full-field stress distribution in and around the joint that cause eventual failure. We are still working on the topic, and more data will be published soon.

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