Three Countermeasures to Address Aluminum Welding Challenges

04 Sep,2026

一 Physical Properties of Aluminum

Atomic Number: 13
Melting Point: Approximately 660°C for pure aluminum
Boiling Point: Approximately 2,519°C
Thermal Conductivity: Approximately 237 W/(m·K) for pure aluminum, with excellent heat conduction
Electrical Conductivity: Approximately 61% IACS for pure aluminum, with good electrical conductivity

二 Characteristics of Aluminum in Welding

High Coefficient of Thermal Expansion: Prone to deformation and hot cracking
Highly Susceptible to Porosity: Pores can easily form during welding
Difficult to Observe the Molten Pool: Making welding operations more challenging
High Reflectivity: Increases the difficulty of laser welding
Softening in the Heat-Affected Zone (HAZ): May reduce the strength of the welded joint

三 Solution 1:

Case 1: 1 mm Aluminum-to-Copper Butt Welding

Welding Results: Ring-light preheating combined with point-light oscillation guides the molten pool to flow steadily and orderly, allowing bubbles to escape from the keyhole in time. This effectively suppresses spatter and porosity defects, resulting in a dense, smooth, and well-formed weld seam.

Case 2: 4 mm Aluminum Plate Butt Welding

Welding Results: Due to aluminum’s high reflectivity, welding can easily result in porosity, molten pool instability, and other defects. The XH-ABMPR Ring-Core 3D Dynamic Adjustable Welding Head, featuring Xinghong’s patented technology, enables stable, high-speed welding with controllable upper and lower weld formation. It delivers uniform, aesthetically pleasing welds while effectively eliminating defects such as spatter, porosity, cracks, weld buildup, and undercut. Combining welding efficiency with finished-product quality, it is well suited for precision welding of various aluminum materials, helping manufacturers reduce costs, improve efficiency, and enhance product competitiveness.

Case 3: Tensile Strength Test of 2 mm 1060 Aluminum Plate Welding

Welding Results: The 2 mm aluminum plate weld achieved a tensile strength of up to 66.2 MPa, while the 2.8 mm aluminum plate weld reached up to 70.9 MPa, demonstrating excellent tensile strength and robust weld joint performance.

四 Solution 2:

Case 1: Comparative Testing of Battery Cover Plate Welding

Single-Mode Welding Head VS. XH-MPR Welding Head

Comparison Test Conclusion: In the single-mode welding test, 1 out of 10 pieces experienced a blowout, while the XH-MPR welding head completed 30 pieces with no blowouts observed, demonstrating significantly improved welding stability and reliability.

Case 2: Comparative Testing of a Dual-Scan Galvo Welding Head and a Dual-Scan Galvo MPR Welding Head

HW30-P VS HW30-P-MPR

Comparison Test Conclusion: With the conventional dual-scan galvo welding head, the metallographic cross-section showed an overall trapezoidal shape with central collapse and a penetration depth of 2 mm. With the XH-MPR welding head, the weld surface remained smooth and free of collapse, while the metallographic cross-section exhibited an overall U-shaped profile with a penetration depth of 1.947 mm.

五 Solution 3:

Case: Filler-Wire Welding of Protective Components for New Energy Vehicle Liquid Cooling Plates

Welding Results: The combination of a welding robot, seam tracking system, HWO30S-P-VI Ring-Shaped Beam Dual-Scan Galvo Welding Head, and wire feeding system solves the challenge of achieving high-quality corner welds. The aluminum protective components of the liquid cooling plate feature smooth, attractive circumferential welds with no porosity or spatter, delivering consistent and reliable welding quality.

六 Typical Laser Welding Applications for Aluminum

1. Transportation
Automotive Lightweighting: Body panels, crash beams, battery housings, etc.
Aerospace: Aircraft skins, frames, structural components
Shipbuilding: Ship superstructures, decks, speedboats

2. Power & Electronics
Busbars, current collector bars, cable sheaths, electronic heat sinks

3. New Energy & Energy Storage
Aluminum battery housings, battery tabs, energy storage battery connectors, liquid cooling plates

4. Machinery & Chemical Industry
Pressure vessels, pipes, tubing, etc.