Laser beam welding of copper foil stacks using a green high power disk laser

Grabmann, Sophie; Tomcic, Lazar; Zaeh, Michael F.

doi:10.1016/j.procir.2020.09.080

Cited by 20 publications

(18 citation statements)

References 10 publications

Supporting

Mentioning

Contrasting

Unclassified

Order By: Relevance

“…Different approaches are currently being discussed to further improve foil welding. Modern high-power laser beam sources in the visible wavelength range (400-780 nm) open up new opportunities for increasing the process reliability of cell internal contacting [11,31].…”

Section: State Of the Artmentioning

confidence: 99%

“…Using a green laser radiation, 30 foils were successfully joined in an overlap configuration [11]. Based on the evaluation of cross sections, it was shown that 20 layers of 8 μm thick copper foils can be welded in a overlap configuration using a blue laser radiation [35].…”

Section: State Of the Artmentioning

confidence: 99%

“…Subsequently, anodes and cathodes are cut out of the electrode coils [9] and are stacked or winded with separator layers [10]. Afterwards, the electrode sheets are mechanically and electrically conductively connected during the cell internal contacting process [11]. For this purpose, the individual uncoated current collector flags of the anodes and the cathodes are welded together and joined to an arrester tab.…”

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Laser welding of current collector foil stacks in battery production–mechanical properties of joints welded with a green high-power disk laser

Grabmann

Kriegler

Harst

et al. 2021

Int J Adv Manuf Technol

Self Cite

View full text Add to dashboard Cite

The qualification of production systems that enable reliable and stable production processes is a major challenge in manufacturing large-format lithium-ion batteries. During cell assembly, the electrode sheets of the anode and the cathode are stacked, and are electrically contacted by a welding process. It was shown that laser beam welding employing a beam source in the green wavelength range is a promising joining approach in terms of high productivity. Therefore, the influence of the process parameters, such as the laser power, the welding speed, the pulse frequency, and the pulse duration, on the weld seam quality was investigated. Particular emphasis was placed on the mechanical strength of the weld seam. Statistically planned experiments were used to determine feasible parameter sets for welding the most common current collectors of lithium-ion battery electrodes, copper (Cu), and aluminum (Al). The influence of the individual process parameters on the tensile shear force was evaluated. Stacks of 40 metal foils were welded with a thin metal sheet in lap joint configuration. Based on an analysis of the requirements for minimum mechanical seam strengths, this study confirms that laser beam welding using a green high-power disk source is an auspicious process for the internal contacting of lithium-ion batteries.

show abstract

Section: State Of the Artmentioning

confidence: 99%

Section: State Of the Artmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Laser welding of current collector foil stacks in battery production–mechanical properties of joints welded with a green high-power disk laser

Grabmann

Kriegler

Harst

et al. 2021

Int J Adv Manuf Technol

Self Cite

View full text Add to dashboard Cite

show abstract

“…When connecting more cells to a battery module, aluminum and copper have to be joined together. Considering pouch cells due to their high volumetric energy density, this implies the joining task of sub-mm thick battery tab connectors, also called arrester tabs [ 11 ].…”

Section: Introductionmentioning

confidence: 99%

Seam Properties of Overlap Welding Strategies from Copper to Aluminum Using Green Laser Radiation for Battery Tab Connections in Electric Vehicles

et al. 2023

View full text Add to dashboard Cite

Laser beam welding of metals has progressed dramatically over the last years mainly arising from joining applications in the field of electromobility. Allowing the flexible, automated manufacturing of mechanically, electrically, and thermally stressed components, the process is more frequently applied for joining highly reflective materials, for example for battery tab and busbar connections. The local, non-contact energy input favors this welding technology; however, joining of copper and aluminum sheets still poses a challenge due to the physical properties of the joining partners and intermetallic phases from dissimilar metal interaction, which reduce seam performance. The use of green laser radiation compared to infrared laser radiation offers the advantage of a significantly increased absorptivity for copper materials. A changed incoupling behavior is observed, and a lower deep penetration threshold has been already proven for 515 nm wavelength. When copper and aluminum are welded with the former as top sheet, this welding mode is essential to overcome limited aspect ratios from heat conduction welding. However, the opportunities of applying these beam sources in combination with spatial power modulation to influence the interconnection area of copper-aluminum joints have not yet been studied. The aim of this work is therefore to investigate the seam properties and process stability of different overlap welding strategies using green laser radiation for dissimilar metal welding. A microstructural analysis of the different fusion zones and mechanical strength of the joints are presented. In addition, the experimental parameter sets were analyzed regarding their application in battery module busbars by examining the electrical resistance and temperature distribution after welding. A parameter window was identified for all investigated welding strategies, with the stitched seam achieving the most stable results.

show abstract

“…One of these materials used as conductive plates is nickel-plated steel plates. Our investigations explore the weldability of this material using a low power 300 W diode laser beam source [1][2][3][4][5][6][7].…”

Section: Introductionmentioning

confidence: 99%

Investigation of nickel coated steel tapes welded joints

Hareancz

Sinka

2022

IOP Conf. Ser.: Mater. Sci. Eng.

View full text Add to dashboard Cite

Nickel-plated steel tapes are primarily developed for battery production. The aim of these developments was to provide all battery cell cases with good contact resistance and high corrosion resistance, thus increasing their durability. When individual battery cells are packaged, the electrical connection is also mostly made with nickel-plated plates. Welding and soldering are the bonding technologies used to make the connections between the plates, but the advantages mentioned above may vary when making these connections. To our knowledge, lasers with diode beam sources are the most efficient and are becoming more and more suitable for a wide range of applications as the technology develops. The aim of our investigations is to investigate the quality of joints made with low power diode lasers with different parameters from a strength and metallographic point of view.

show abstract

Laser beam welding of copper foil stacks using a green high power disk laser

Cited by 20 publications

References 10 publications

Laser welding of current collector foil stacks in battery production–mechanical properties of joints welded with a green high-power disk laser

Laser welding of current collector foil stacks in battery production–mechanical properties of joints welded with a green high-power disk laser

Seam Properties of Overlap Welding Strategies from Copper to Aluminum Using Green Laser Radiation for Battery Tab Connections in Electric Vehicles

Investigation of nickel coated steel tapes welded joints

Contact Info

Product

Resources

About