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In fact, a single vehicle typically contains 2000–5000 spot welds according to Chao (2003). In Li-ion battery packs, metal-to-metal joints are formed using joining technologies such as electrical resistance spot welding (RSW), arc welding, laser welding, self-piercing rivets, and mechanical clinching as reported by Qiu et al. (2009).
In Li-ion battery packs, metal-to-metal joints are formed using joining technologies such as electrical resistance spot welding (RSW), arc welding, laser welding, self-piercing rivets, and mechanical clinching as reported by Qiu et al. (2009). Unfortunately, joining Cu to Al presents technical challenges when these conventional processes are used.
Laser welding is an efficient and precise welding method using high energy density laser beam as heat source. Due to heat concentration, fast welding speed, small thermal effect, small welding deformation, easy to realize efficient automation and integration [15, 16, 17], it is more and more widely used in power battery manufacturing. Figure 1.
There are many parts that need to be connected in the battery system, and welding is often the most effective and reliable connection method. Laser welding has the advantages of non-contact, high energy density, accurate heat input control, and easy automation, which is considered to be the ideal choice for electric vehicle battery manufacturing.
Because the common material of the battery housing is steel and aluminum and other refractory metals, it will also face various problems. In this paper reviews, the challenges and the latest progress of laser welding between different materials of battery busbar and battery pole and between the same materials of battery housing are reviewed.
However, the welding of aluminum alloy has been facing various challenges because aluminum alloy has good thermal conductivity and high coefficient of thermal expansion, making it difficult to weld. Aluminum alloy welding is usually accompanied by cracks and pores and other welding defects [66, 67, 68, 69].
Aluminum is a superstar in the electric vehicle revolution, as highlighted in the …
In Li-ion battery packs, metal-to-metal joints are formed using joining …
This paper discusses research trends in laser welding technology for joining Al and Cu, which is currently applied for the joining process in the …
Study and Characterization of EN AW 6181/6082-T6 and EN AC 42100-T6 aluminum alloy welding of structural applications: metal inert gas (MIG), cold metal transfer …
Therefore, when welding aluminum alloys with a high tendency for cracking, it is not advisable to use high welding currents or fast welding speeds. 3) Choosing structural …
A wide range of research shows that the laser welding of busbar to battery tabs is a very promising technique. It can enhance the battery module''s safety and reliability owing to its unique...
In order to solve the problems of forming porosity and poor welding stability in the welding process of aluminum alloy, Wu et al. proposed a new welding method. They used …
2024-T3 aluminum alloy 500–638 121 23.2 6061-T6 aluminum alloy 580–650 167 23.6 7075-T6 aluminum alloy 475–635 130 23.6 Pure Fe 1538 80.4 11.7 SAE 1020 carbon steel 1470–1530 …
In order to solve the problems of forming porosity and poor welding stability in the welding process of aluminum alloy, Wu et al. proposed a new welding method. They used fiber laser with focused rotation and vertical …
The application of aluminum alloy MIG welding technology in the electric vehicle battery box effectively improves the welding efficiency and reduce the cost of production.
This paper reviews current challenges and opportunities for construction of battery tray using aluminium alloys with laser welding process. It aims to provide a view on the …
The development of real-time laser welding monitoring technology is crucial to increase productivity and enable the mass production of reliable electric vehicle battery systems. Key …
Improving the performance of electric vehicles requires the development of automotive batteries and battery joining technologies. Aluminum alloys are the most widely used metals in the …
In Li-ion battery packs, metal-to-metal joints are formed using joining technologies such as electrical resistance spot welding (RSW), arc welding, laser welding, self-piercing …
A wide range of research shows that the laser welding of busbar to battery tabs is a very promising technique. It can enhance the battery module''s safety and reliability owing …
Compared with separate laser welding or GMA welding methods, laser-arc hybrid welding not only has the advantages of the two methods but also has additional advantages …
The development of real-time laser welding monitoring technology is crucial to increase …
Also, filler alloys should be resistant to hot tears and provide enough strength and ductility. In the welding of low alloy aluminum alloys (e.g., 1XXX series), almost exclusively alloy Al1100 is used [62]. 1xxx series (i.e., 1050, 1060, 1100) and …
The application of aluminum alloy MIG welding technology in the electric vehicle battery box …
This paper discusses research trends in laser welding technology for joining Al and Cu, which is currently applied for the joining process in the battery pack manufacturing.
Research progress of aluminum alloy welding technology Yiwen Li1 & Wenfeng Zou1 & Boyoung Lee2 & Aleksandr Babkin3 & Yunlong Chang1 Received: 11 September 2019/Accepted: 8 …
PDF | On Jan 1, 2009, G. J Shannon published Laser welding of aluminum and copper for battery welding applications using a 500W single mode fiber laser | Find, read and cite all the research you ...