A first abutting surface, a first welding surface, a first facing surface are formed in a differential case. A second abutting surface, a second welding surface, and a second facing surface are formed in a differential ring gear. In an installing step, the first abutting surface and the second abutting surface are inserted, positions of the differential case and the differential ring gear are determined in an axial direction, a separation portion that spaces the first welding surface and the second welding surface away from each other and that has a non-linear portion is formed, and a void is formed between the first facing surface and the second facing surface. In a welding step, a laser is irradiated to the separation portion and the first welding surface and the second welding surface are welded.

Laser welding of a first metal substrate having a first planar surface and a second planar surface disposed opposite the first planar surface to a second metal substrate is performed by placing an end face of the second metal substrate proximate to the first planar surface. An input laser beam from a fiber laser is generated, and a beam delivery system is provided that is configured to receive the input laser beam and generate an output laser beam having a beam spot that moves in a predetermined pattern along a first and a second axes to irradiate a target area on the second planar surface such that the target area is positioned over an intersection region of the first planar surface where the end face is positioned proximate to the first planar surface.

Laser welding of a first metal substrate having a first planar surface and a second planar surface disposed opposite the first planar surface to a second metal substrate is performed by placing an end face of the second metal substrate proximate to the first planar surface. An input laser beam from a fiber laser is generated, and a beam delivery system is provided that is configured to receive the input laser beam and generate an output laser beam having a beam spot that moves in a predetermined pattern along a first and a second axes to irradiate a target area on the second planar surface such that the target area is positioned over an intersection region of the first planar surface where the end face is positioned proximate to the first planar surface.

A braze-free substrate heating device including a heater block body, a heater block lid, and a heating element. The heating element sits inside the heater block body. The heater block lid is on the heating element, such that the heating element is sandwiched between the heater block lid and the floor of the heater block body. The heating element is held in place by compressing the heater block lid into the heater block body and attaching the heater block lid to the top of the heater block body so that the heating element is fully supported over its surface area, and can maintain uniform thermal contact with the heater block lid and heater block body over its entire surface area.

Welded parts and methods of manufacturing the same are disclosed. A welded part may include first and second metal workpieces having respective first and second edges forming a butt joint. The welded part may further include a first laser weld joining the first and second edges on one side of the first and second metal workpieces, and a second laser weld joining the first and second edges on another opposite side of the first and second metal workpieces. Some example parts may have laser welds that cooperate to extend across an entire depth of the butt joint and form an overlap zone between the first and second laser welds. In some examples, the first and second laser welds may be formed with substantially zero macroporosity.

A welding method includes: arranging a workpiece containing copper in a region to be irradiated with laser light; and irradiating the workpiece with the laser light to melt and weld an irradiated portion of the workpiece. Further, the laser light is formed of a main beam and a plurality of sub beams, and a ratio of power of the main beam to total power of the plurality of sub beams is 72:1 to 3:7.

A welded joint comprising an aluminum-based base material comprising an aluminum alloy or pure aluminum and a copper-based base material comprising a copper alloy or pure copper joined by a weld metal portion is provided. The weld metal portion contains copper in ranges of less than 75% by mass and silicon in ranges of less than 13% by mass and has a higher content of copper and silicon than the aluminum-based base material.

A welded joint comprising an aluminum-based base material comprising an aluminum alloy or pure aluminum and a copper-based base material comprising a copper alloy or pure copper joined by a weld metal portion is provided. The weld metal portion contains copper in ranges of less than 75% by mass and silicon in ranges of less than 13% by mass and has a higher content of copper and silicon than the aluminum-based base material.

A method for the remote laser welding of at least two metal sheets, where at least one metal sheet has a coating with a low boiling point, in particular for welding galvanized steel sheets, includes moving a laser beam at a welding velocity along a welding contour in order to produce a weld seam. The laser beam executes an oscillating movement which is superposed on the welding velocity, where the energy input into the joint is controlled by a power modulation, dependent on the oscillating movement, such that the energy input increases in at least one lateral oscillation periphery or a preceding oscillation periphery of the melt bath volume, but the size of the melt bath surface in the root area remains unaffected.

A method for the remote laser welding of at least two metal sheets, where at least one metal sheet has a coating with a low boiling point, in particular for welding galvanized steel sheets, includes moving a laser beam at a welding velocity along a welding contour in order to produce a weld seam. The laser beam executes an oscillating movement which is superposed on the welding velocity, where the energy input into the joint is controlled by a power modulation, dependent on the oscillating movement, such that the energy input increases in at least one lateral oscillation periphery or a preceding oscillation periphery of the melt bath volume, but the size of the melt bath surface in the root area remains unaffected.