Fusion Welding of Thin Metal Foils

This paper reviews some of the problems associated with the fusion welding of thin metal foils and describes the current techniques employed at LASL to join foils. Techniques for fusion welding 0.025 mm-thick foils of copper, aluminum and stainless steels have been developed using both electron beam and laser welding equipment. These techniques together with the related aspects of joint design, tooling and fixturing, joint preparation and some necessary modifications to the commercially available welding equipment, are included in the review.