Abstract Scope |
Batteries used in E-mobility applications are generally prismatic with combinations of copper, aluminum, or nickel tabs, or cylindrical with either steel or aluminum shells. Interconnection of these batteries to produce packs can be very easy; for example, nickel tabs to steel shells is a mature resistance welding process. More difficult material combinations involve dissimilar metal welds of copper to aluminum, aluminum to steel, and others. Though welding processes have been developed for many of these combinations, all have some limitations.
EWI addressed these limitations by evaluating pulsed arc welding for several tab – battery material combinations. The welding pulse shapes were investigated to accurately control weld penetration and weld solidification behavior. Welding process monitoring was also investigated to ensure weld joint quality for each of the hundreds of welds required by a large array battery module. In this presentation, the pulsed arc welding process will be described, the various joint combinations and weld data will be discussed, and recommendations will be provided for real world battery pack applications. |