Technical Paper
Parameter Optimization and Characterization of Aluminum-Copper Laser Welded Joints
2024-04-09
2024-01-2428
As the automotive industry accelerates its shift towards electric vehicles (EVs) in order to mitigate greenhouse gas emissions, there is an escalating need for innovative approaches in manufacturing critical components, particularly battery packs. Battery packs of electric vehicles are typically composed of lithium-ion batteries with aluminum and copper acting as cell terminals. These terminals are joined together in series by means of connector tabs to accommodate sufficient power and energy output. These critical electrical and structural cell terminal connections involve several challenges when joining the thin, highly reflective and dissimilar materials with widely differing thermo-mechanical properties. This may involve potential deformation during the joining process, the formation of brittle intermetallic compounds with reduced conductivity and inferior mechanical properties.