This discusses investigations regarding flexible and efficient strategies of laser remote welding of ultra-thin metal foils (≤ 50μm) which are applied in the fields of electronics, packaging, and construction. A single-mode fiber laser was used, equipped with a scanner head and diverse objectives. Thus, different optical settings and material thicknesses could be tested and compared with regard to process stability, reliability and efficiency. The long-term stability of the optical setting was determined related to focus shift and beam shape in the working plane. The specimens were analyzed with methods of micro-sections, microhardness and tensile strength tests. In this way, it could be shown that laser remote welding of ultra-thin metal foils is a well-suited modern technology which is able to substitute former slower or inflexible techniques respectively compound materials with a high in-house production depth.
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