Joining of lithium-ion batteries using laser beam welding: Electrical losses of welded aluminum and copper joints

Schmidt, Philipp; Schweier, M.; Zaeh, Micheal F.

doi:10.2351/1.5062563

Cited by 46 publications

(40 citation statements)

References 9 publications

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“…For battery assemblies, joining of two different metals can be required, e.g., an aluminum cell terminal with a copper external conductor [31]. When laser beam welding is used, the two molten materials are mixed and a metallurgical system is generated, which influences the mechanical properties.…”

Section: Suitability Of Laser Beam Welding For Connecting Battery Cellsmentioning

confidence: 99%

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Welding techniques for battery cells and resulting electrical contact resistances

Brand

Schmidt

Zaeh

et al. 2015

Journal of Energy Storage

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161

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Section: Suitability Of Laser Beam Welding For Connecting Battery Cellsmentioning

confidence: 99%

“…Laser beam welding allows widely arbitrary weld geometries which can be optimized for every application [31]. Furthermore, battery tabs or connector bars with a thickness of several millimeters can be joined by keyhole welding [25,28].…”

Section: Suitability Of Laser Beam Welding For Connecting Battery Cellsmentioning

confidence: 99%

Welding techniques for battery cells and resulting electrical contact resistances

Brand

Schmidt

Zaeh

et al. 2015

Journal of Energy Storage

Self Cite

161

View full text Add to dashboard Cite

“…Another method to achieve high peak intensities is the use of single mode fiber lasers with maximum intensities of up to 10 12 W/cm² [12,13]. In scanner-based remote laser welding, high-frequency beam oscillations are often used to adjust a specific weld geometry [14,15].…”

Section: Variable Methodsmentioning

confidence: 99%

Laser Welding of Copper Using Multi Mode Fiber Lasers at Near Infrared Wavelength

et al. 2014

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Due to the increasing electrification of automotive drives and the expansion of decentralized renewable energy generation, the consumption of copper for the fabrication of electrical components such as electric motors or conducting paths increases. To join these components, laser welding is more frequently used since it represents a flexible and fully automatable joining process. Because of the high thermal conductivity, the low absorption coefficient for infrared wavelength of common laser beam sources and the resulting limited process efficiency, welding of copper alloys represents a major challenge for laser assisted processes. In this paper, experimental investigations are presented to identify arising process limits during laser welding of pure copper materials with multi-mode fiber lasers at near infrared wavelength depending on the applied laser power and welding velocity. In addition, a potential stabilization of the welding process by shielding gas support was examined. Further investigations were focused on the influence of shielding gas on the molten pool geometry.

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“…With the potential difference between two points and a given electric current the resistance for the contact geometry can be determined [12]. The following basic equations (1)(2)(3)(4)(5) are implemented in the thermo-electric FEM simulation. The thermal heating is…”

Section: Electro-thermal Fem Simulationmentioning

confidence: 99%

“…The remote laser beam welding process offers the opportunity to vary the contact area as well as its position in the joining zone. Further studies [5,6] showed a significant dependence of the geometrical shape of the contact area and the contact resistance. The prediction of the optimised shape of the contact area is very complex regarding threedimensional contact configurations.…”

Section: Introductionmentioning

confidence: 99%

Optimisation of Weld Seam Configurations Using a Genetic Algorithm

Schmidt¹,

Pauleser²,

Zaeh³

2014

Procedia CIRP

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The main task of high performance electrical contacts is the transmission of electrical power with low power dissipation. The decisive value to calculate the electrical losses of a contact is the resistance of the contact configuration. The electrical resistance can be decreased applying laser welded connections. This promising joining technology offers the opportunity to vary the contact area as well as its position in the joining zone. Especially the geometrical shape of the contact area enables a high potential to reduce the contact resistance. This work presents a method to optimise the geometrical shape of the weld seam in order to minimise the resistance of the electrical contact. A solution is proposed to calculate the optimum weld seam shape by the use of a genetic algorithm (GA) linked with an electro-thermal FEM simulation. The genetic algorithm compiles alternative weld seam shapes while the FEM simulation determines their electro-thermal properties. The optimised result is further verified within an experimental study. The proposed method is applied to design the electrical contacts between battery cells of a high voltage automotive battery system for electric and hybrid electric cars.

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Joining of lithium-ion batteries using laser beam welding: Electrical losses of welded aluminum and copper joints

Cited by 46 publications

References 9 publications

Welding techniques for battery cells and resulting electrical contact resistances

Welding techniques for battery cells and resulting electrical contact resistances

Laser Welding of Copper Using Multi Mode Fiber Lasers at Near Infrared Wavelength

Optimisation of Weld Seam Configurations Using a Genetic Algorithm

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