Improving electric vehicle battery efficiency through laser welding

Improved electric vehicle battery performance is a major factor in the steady growth of electric vehicle sales. Better performance stems in part from recent developments in laser welding of dissimilar metals, which improves efficiency by increasing energy storage, reducing size and maintaining reliability. In fact, welding less resistive metals to the standard stainless steel terminals of lithium-ion batteries can reduce resistance and improve battery efficiency. However, traditional resistance spot welding cannot effectively join highly conductive dissimilar metals, such as copper and aluminum, because the resulting intermetallic mixture is brittle. But lasers can do the job with amazing results!

 

Improving electric vehicle battery efficiency through laser welding

 

Both CW and pulsed fiber lasers are capable of successfully joining dissimilar metals. The key is to use high power and very short pulses to join the parts without melting the metal.

The image below, achieved using a 500W single-mode continuous wave fiber laser, shows a cross-section of an aluminum and steel spiral welded joint that looks much like a multi-pile profile. The actual laser weld profile is highlighted in yellow.

Semi-automatic welding line for lithium battery module

Weld profile

Low power (70 W) pulsed lasers can be used to join thin dissimilar metals. Pulsed lasers are characterized by a small spot size, use more joints to produce the same contact area in the weld zone, and ensure proper weld strength at the material interface. The resulting weld profile is very similar to the riveting process. The joints are mainly mechanical, with a transition zone width between the metals of less than 10 microns, avoiding the formation of brittle intermetallic compounds. Despite the small individual welds, the technique produces a single layer shear strength of about 10 lbs (44 N). In addition to aluminum/steel, potential welding combinations include copper/steel, titanium/steel, copper/titanium and copper/aluminum.

It is expected that this advanced laser welding technology will continue to drive the efficiency of electric vehicles in the short and long term.

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