About this Abstract |
| Meeting |
2026 TMS Annual Meeting & Exhibition
|
| Symposium
|
Advanced Real Time Imaging for Materials Science and Processing
|
| Presentation Title |
Ultra-fast correlative X-ray and inline coherent imaging of electric vehicle welding |
| Author(s) |
Zhengrui Tao, Iurii Markushov, Hui-Chi Chen, Sebastian Marussi, Tristan Fleming, Andrey Gorskiy, Aleksandr Oreshkin, Emma Howard, Kwan Kim, Shishira Bhagavath, Alexander Rack, Diego Hopson Safatli, Peter D. Lee, Chu Lun Alex Leung |
| On-Site Speaker (Planned) |
Chu Lun Alex Leung |
| Abstract Scope |
Keyhole-mode laser welding of dissimilar materials, e.g. Al & Cu, is a key enabling technology for electric vehicle (EV) manufacturing. While keyhole-mode welding can overcome the highly reflective materials and achieve sufficient weld penetration, it is prone to keyhole instability, which often leads to imperfections, e.g. porosity. Porosity can lower the electrical and mechanical properties of a weld, posing a significant threat to vehicle safety. To gain deeper insights into these mechanisms, UCL and IPG Photonics have developed a physical twin of the EV welding process, which integrates a high-power welding optical module, adjustable mode beam (AMB) lasers (up to 8 kW) and Inline Coherent Imaging (ICI) (250 kHz). We performed correlative ICI and ultra-fast synchrotron X-ray imaging at 200 kHz to quantify the keyhole dynamics underlying defect formation during EV welding. We will present our results and their potential to enable faster, more reliable, and defect-lean EV welding components. |
| Proceedings Inclusion? |
Planned: |
| Keywords |
Joining, Characterization, Process Technology |