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Laser Overlap Welding of Tab-to-Terminal Electrical Interconnects for Electric Vehicle Battery Pack Open
A battery pack consists of several Li-ion cells connected, with laser welding being the preferred method for creating strong and durable joints. This paper investigates laser overlap welding for producing tab-to-terminal interconnects for …
Influence of nickel-plating on laser weldability of aluminium busbars for lithium-ion battery interconnects Open
This study investigates the influence of nickel-plating method and thickness on the laser weldability of aluminium busbars for lithium-ion battery cell interconnects. Three nickel plating methods (electroless medium phosphorus, electrolyti…
Analysis of Stirring Action to Control Grain Refinement of Inconel 625 Superalloy Bead on Plate Using Laser Wobble Technology Open
In this paper, the influence of various laser wobbling patterns, such as circle, ellipse, figure eight, bowtie, Celtic, flower, atomic, hexagon, triangle and star, on grain refinement mechanisms during welding of Inconel 625 sheets is eval…
In-depth evaluation of laser welding of thick busbar to 21700 Li-ion cell terminal for electric supercar vehicle battery pack Open
High-performance supercars using Li-ion batteries necessitate thicker aluminium busbars with thin steel joints. However, joining these materials often leads to overheating resulting in brittle intermetallic compounds (IMCs), reduced weld q…
Dual-mode laser beam welding of similar and dissimilar material tab-to-busbar for electric vehicle battery pack Open
The escalation in electric vehicle (EV) adoption necessitates advanced laser joining techniques for critical battery pack components. However, using a standard Gaussian single-mode laser for joining similar and dissimilar material combinat…
A modelling approach for laser welding of busbars to lithium-ion prismatic cell terminals to enhance failure prediction Open
Laser welding is increasingly being used to connect automotive battery packs and weld busbars to prismatic cell terminals due to its ability to weld a wide variety of materials at high speed. The choice of material for the connecting busba…
Laser Doppler Vibrometry for Evaluating the Quality of Welds in Lithium-Ion Supercells Open
The inspection of the quality of welds in battery packs plays an important role in ensuring safety during the manufacturing and operation of energy-storage devices in automotive vehicles during service. This research investigated the novel…
Substituting Resistance Spot Welding with Flexible Laser Spot Welding to Join Ultra-Thin Foil of Inconel 718 to Thick 410 Steel Open
This paper investigated various aspects of replacing existing micro-resistance spot welding (micro-RSW) with micro-laser spot welding for joining Inconel 718 thin foils to thick 410 steel stack-up to allow faster, non-contact joining toget…
Laser wobble welding of steel to Aluminium busbar joints for Li-ion battery packs Open
In this work, Laser wobble welding of Steel to Aluminium busbar joints was investigated for Li-ion battery pack applications. The effect of wobble amplitude on the properties of the weld was studied. It is observed that wobble amplitude si…
Macro-Modelling of Laser Micro-Joints for Understanding Joint Strength in Electric Vehicle Battery Interconnects Open
Laser micro-welding is increasingly being used to produce electrically conductive joints within a battery module of an automotive battery pack. To understand the joint strength of these laser welds at an early design stage, micro-joints ar…
Methodology for Developing a Macro Finite Element Model of Lithium-Ion Pouch Cells for Predicting Mechanical Behaviour under Multiple Loading Conditions Open
To assist in light weighting of electric vehicles by improving the volumetric and gravimetric energy density and the structural performance of the battery pack, a modelling methodology based on a macro finite element model of a pouch cell …
Additive Manufacture of 3D Auxetic Structures by Laser Powder Bed Fusion—Design Influence on Manufacturing Accuracy and Mechanical Properties Open
The mechanical response of steel auxetic structures manufactured using laser-powder bed fusion was explored. The level of control exerted by the key design parameters of vertical strut length (H), re-entrant strut length (L), strut thickne…
Dynamic Mechanical Compression Impulse of Lithium-Ion Pouch Cells Open
Strain rate sensitivity has been widely recognized as a significant feature of the dynamic mechanical properties of lithium-ion cells, which are important for their accurate representation in automotive crash simulations. This research sou…
Feasibility of Fillet Edge Weld Using Laser Wobble Technique Open
In many industrial applications, especially for automotive, aerospace and electronics, laser welding is the preferred joining process due to its high flexibility, short process time and high precision. In conventional single-mode laser wel…
Direct Observation via In Situ Heated Stage EBSD Analysis of Recrystallization of Phosphorous Deoxidised Copper in Unstrained and Strained Conditions Open
Recrystallization of phosphorous deoxidised copper used for strength critical applications at elevated temperatures was investigated by means of in situ heated stage EBSD analysis using a Gatan Murano heated stage mounted within a Carl Zei…
Comparison of Tab-To-Busbar Ultrasonic Joints for Electric Vehicle Li-Ion Battery Applications Open
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 c…
Influence of Elevated Temperatures on Mechanical Properties and Microstructure of C106 Copper Investigated by In Situ Heated Stage EBSD Analysis Open
This study presents two analogs of extant industrial thermomechanical cycles to look at the microstructural evolution of C106 phosphorous deoxidized copper throughout. Vickers hardness testing was employed to assess the influence on post-f…
Comparison of Formability and Microstructural Evolution of C106 Copper and 316L Stainless Steel Open
Strain hardenable materials achieve their strength due to the build-up of defects and dislocation tangles within the microstructure brought about by induced strain through processing or forming. This strength can be significantly reduced a…
Picosecond Pulsed Laser Ablation of Liquid Covered Stainless Steel: Ef-fect of Liquid Layer Thickness on Ablation Efficiency Open
Under liquid laser ablation is a material removal technique in which a focused laser beam passes through a liquid layer on top of the surface of a sample to be processed. When compared to laser ablation without a liquid layer, material (re…
Investigation of Laser Processing of Biodegradable Nanofiber Nonwovens with Different Laser Pulse Durations Open
Implants or cell carriers made of biopolymers or biodegradable polymers are well suited for the regeneration of defects in various tissues. They act as an adhesion surface for autologous cells and provide sufficient stability. Electrospun …
High-Efficiency Sub-Micrometer Multi-Beam Interference Structuring for Large-Scale Surface Using Ultrashort Laser Pulses Open
Laser direct structuring using multi-beam interference can fabricate one and two-dimensional periodic patterns with a structural periodicity from hundred nanometer to tens of micrometer. Never-the-less, the structuring efficiency, which is…
Evaluation of Key Geometrical and Mechanical Properties for Remote Laser Welded AC-170PX Aluminium Joints Open
Use of lightweight materials to produce automotive body structures is one of the key trends adopted by automotive manufacturers to minimise emission of greenhouse gases, and subsequently, reduction of fuel consumption. Aluminium alloys are…
Process robustness and strength analysis of multi-layered dissimilar joints using ultrasonic metal welding Open
This paper investigates the effects of process parameters on the joint strength and process robustness when multi-layered joints of dissimilar metals are produced by ultrasonic metal welding (UMW). Three layers of 0.3-mm aluminium sheet ar…