Al-Cu 겹치기 레이저 용접 공정에서 지그 구조가 밀착력과 용접 품질에 미치는 영향에 관한 연구

Abstract

This study investigates the influence of jig structure on clamping quality and weld performance in aluminum-copper overlap laser welding system. Two types of jig designs—cantilever and fixed-fixed—were compared under identical welding conditions. A series of evaluations including pressure-sensitive film tests, weld surface inspection, penetration depth analysis using LDD equipment, and finite element method (FEM) simulations were conducted. The cantilever jig exhibited inconsistent clamping pressure toward the free end, leading to weak weld bead formation, insufficient penetration, and in some cases, material delamination. In contrast, the fixed-fixed jig maintained uniform clamping across the weld zone, resulting in stable penetration depths and consistent weld appearance without any delamination. FEM analysis confirmed that the cantilever jig caused localized stress concentration and reduced contact pressure at the free end, whereas the fixed-fixed jig provided uniform pressure distribution throughout. These results demonstrate that jig structure plays a critical role in determining heat transfer, fusion consistency, and joint integrity in dissimilar metal welding. The findings provide practical guidance for jig design optimization, particularly in industries requiring high-reliability welds such as battery modules and automotive electrical components.