Joining Technologies for Automotive Battery Systems Manufacturing

Das, Abhishek; Li, Dezhi; Williams, David; Greenwood, David

doi:10.3390/wevj9020022

Cited by 185 publications

(128 citation statements)

References 26 publications

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“…Suitable joining methods for pouch cell tab-to-tab interconnects, such as ultrasonic metal welding, resistance spot welding and pulsed TIG spot welding [9,10], are selected as candidate methods for this feasibility study. The advantages, disadvantages and challenges of these joining methods are summarised in Table 1.…”

Section: Overview Of Joining Methodsmentioning

confidence: 99%

Weldability and shear strength feasibility study for automotive electric vehicle battery tab interconnects

Das

Williams

et al. 2019

J Braz. Soc. Mech. Sci. Eng.

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Lithium-ion-based secondary battery packs are emerging as an alternative power source and are being increasingly used in electric vehicles, hybrid or plug-in hybrid electric vehicles. Typically, a standard automotive battery pack consists of hundreds, even thousands, of individual cells which are connected in series and/or parallel to deliver the required power and capacity. There is an increasing need for manufacturing of battery packs to meet the demand reflecting the uptake of these vehicles. This triggers the need for suitable joining methods which will provide mechanical strength on a par with electrical and thermal characteristics. This work focuses on characterisation of shear strength of battery tab-to-tab joints for both similar and dissimilar materials by using combinations of aluminium (Al) and nickel-coated copper (Cu[Ni]) tabs. The joining techniques with application for battery tab interconnects are ultrasonic metal welding, resistance spot welding and pulsed TIG spot welding. Lap shear and T-peel tests are performed to evaluate the joint strength. In general, lap shear strength is four to seven times higher than the T-peel strength obtained from all three joining methods. In addition, an indicator is developed in this paper based on lap shear-to-T-peel strength reduction ratio which provides additional information on joint strength characteristics, and subsequently, it can be used as a threshold by quality engineers for an indication on selection of joining methods having an acceptable strength reduction ratio.

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Section: Overview Of Joining Methodsmentioning

confidence: 99%

Weldability and shear strength feasibility study for automotive electric vehicle battery tab interconnects

Das

Williams

et al. 2019

J Braz. Soc. Mech. Sci. Eng.

Self Cite

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“…In turn, the microTIG method has been used in the aviation industry to regenerate thin titanium sensors, for which it is required to limit the amount of heat introduced and to obtain narrow weld beads [15]. Another example of the application of this method is welding elements of car battery cells used in electric vehicles [16] or regeneration of matrix edges in hard to reach areas where the mobility of the operator's hand movements allows reaching certain places in a more efficient and faster way [17].…”

Section: Introductionmentioning

confidence: 99%

Remanufacturing and surface modification in micro-areas by laser beam and microTIG methods

Połaski

Jakubowski

2020

Weld. Tech. Rev.

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Over the past years, intensive development of welding technologies that enable precise impact on the workpiece has been observed. The laser technology is the most known and commonly used tool for precise machining, both in terms of obtaining the appropriate geometry and heat distribution. This technology is now easily available, but it still has many limitations in its "basic edition". An attractive alternative in machining micro-areas can be the arc method ‒ microTIG, which is a modification of the TIG method.The work compares the effects of cladding of selected pairs of substrate materials using the microTIG method and a laser beam. The results of microscopic tests and hardness measurements of deposits made with a laser beam and the microTIG method are presented. The advantage of cladding with the microTIG method was the possibility of obtaining deposits with a lower dilution of the substrate material in the clad weld compared to laser cladding. On the other hand, clad welds produced with the laser beam had a significantly smaller amount of welding defects.

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“…Lithium-ion (Li-ion) electrochemistry-based secondary batteries are now widely used for electrification of automotive vehicles due to several advantages, including high energy density, low self-discharge and portability [1,2]. Greenhouse gases emission legislation has driven the automotive industry to develop fully electric vehicles (EV), hybrid or plug-in hybrid electric vehicles (HEV/PHEV) with low carbon emissions [3,4].…”

Section: Introductionmentioning

confidence: 99%

Comparison of Tab-To-Busbar Ultrasonic Joints for Electric Vehicle Li-Ion Battery Applications

Das

Barai

Masters

et al. 2019

WEVJ

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Recent uptake in the use of lithium-ion battery packs within electric vehicles has drawn significant attention to the selection of busbar material and corresponding thickness, which are usually based on mechanical, electrical and thermal characteristics of the welded joints, material availability and cost. To determine joint behaviour corresponding to critical-to-quality criteria, this study uses one of the widely used joining technologies, ultrasonic metal welding (UMW), to produce tab-to-busbar joints using copper and aluminium busbars of varying thicknesses. Joints for electrical and thermal characterisation were selected based on the satisfactory mechanical strength determined from the T-peel tests. Electrical contact resistance and corresponding temperature rise at the joints were compared for different tab-to-busbar joints by passing current through the joints. The average resistance or temperature increase from the 0.3 mm Al tab was 0.6 times higher than the 0.3 mm Cu[Ni] tab, irrespective of busbar selection.

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Joining Technologies for Automotive Battery Systems Manufacturing

Cited by 185 publications

References 26 publications

Weldability and shear strength feasibility study for automotive electric vehicle battery tab interconnects

Weldability and shear strength feasibility study for automotive electric vehicle battery tab interconnects

Remanufacturing and surface modification in micro-areas by laser beam and microTIG methods

Comparison of Tab-To-Busbar Ultrasonic Joints for Electric Vehicle Li-Ion Battery Applications

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