About this Abstract |
| Meeting |
11th Conference on Trends in Welding Research + Additive Manufacturing (TWR+AM)
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| Symposium
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11th Conference on Trends in Welding Research + Additive Manufacturing (TWR+AM)
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| Presentation Title |
Interfacial Contact and Compliance Govern Keyhole Stability in Multilayer Foil Laser Welding |
| Author(s) |
Alisha Bhatt, Rakesh R. Kamath, Tianzhao Wang , Samuel J. Clark , Wei Zhang , Andrew Chihpin Chuang , Kamel Fezzaa , Yong Chae Lim , Jian Chen , Hassan Ghassemi Armaki , Masoud M. Pour, Blair Carlson , Zhili Feng , Dileep Singh |
| On-Site Speaker (Planned) |
Alisha Bhatt |
| Abstract Scope |
High-energy-density electric vehicle batteries rely on robust joining of multilayer aluminum (Al) current collectors, yet defect formation during laser welding remains difficult to predict due to complex interfacial and dynamic effects. In this work, operando synchrotron X-ray imaging is used to resolve keyhole and melt-pool dynamics during laser welding of multilayer Al foils to tabs.
The results show that keyhole instability is the primary driver of pore nucleation, growth, and coalescence. Interfacial gaps and stack rigidity influence defect evolution by modulating melt flow and keyhole stability. Ultrasonic pre-consolidation increases porosity by promoting interfacial separation and suppressing conformal contact, leading to unstable dual-sided melting and lack of fusion. Based on these insights, a defect-regime map correlates linear energy input and interfacial state with dominant failure modes, including porosity, lack of fusion, and burn-through. This framework provides a transferable process design strategy for multilayer foil welding and broader laser-based manufacturing. |
| Proceedings Inclusion? |
Undecided |