Characterization of Kovar-to-Kovar laser welded joints and its mechanical strength

For the packaging of a pump laser in butterfly package, the most crucial assembly step is the fiber-to-laser diode coupling and attachment. The use of laser welding as the joining method offers several advantages if compared with the adhesive joints: strong joining strength, short process time and less contamination. This paper reports on laser welding process characteristics; weld strength and its fracture mode. The penetration depth and melt area of laser spot welds were found to be complicated functions of laser pulse energy, intensity, and beam diameter. Effects of pulse width, input power and size of the focal spot on the rate of energy input to the workpieces and consequently, the weld strength were reported. The weld strength was found to be dependent on the overlapping area between the two joining materials. Surface roughness, R_a, has influence on the fraction of energy absorbed, A, and therefore, affecting the penetration depth. Thermal analysis was carried out on the laser-welded joints and its heat-affected zone (HAZ) induced by various power densities was examined. These data are important in order to optimize and utilize the laser welding process as an effective manufacturing tool for fabrication of reliable pump laser.