Laser welding of aluminum alloys

Recent interest in reducing the weight of automobiles to increase fuel mileage has focussed attention on the use of aluminum and associated joining technologies. Laser beam welding is one of the more promising methods for high speed welding of aluminum. Consequently, substantial effort has been expended in attempting to develop a robust laser beam welding process. Early results have not been very consistent in the process requirements but more definitive data has been produced recently. This paper reviews the process parameters needed to obtain consistent laser welds on 5000 series aluminum alloys and discusses the research necessary to make laser processing of aluminum a reality for automotive applications.