About this Abstract |
| Meeting |
2027 TMS Annual Meeting & Exhibition
|
| Symposium
|
Advanced Real Time Imaging for Materials Science and Processing: 10th Anniversary
|
| Presentation Title |
Mechanisms of Porosity Formation in Laser Welding of Multilayer Aluminium and Copper Battery Current Collectors Revealed by Operando X-ray Imaging |
| Author(s) |
Alisha Bhatt, Rakesh Kamath, Tianzhao Wang , Samuel Clark , Wei Zhang, Andrew Chuang, Kamel Fezzaa, Yong Chae Lim, Jian Chen, Hassan Ghassemi-Armaki, Masoud Pour, Blair Carlson, Zhili Feng, Dileep Singh |
| On-Site Speaker (Planned) |
Alisha Bhatt |
| Abstract Scope |
Reliable joining of multilayer metallic foils is critical for battery manufacturing, yet defect formation during laser welding remains poorly understood because interfacial heterogeneities affect keyhole and melt-pool stability. Here, operando synchrotron X-ray imaging directly visualizes keyhole evolution, melt flow, and pore formation during laser welding of multilayer aluminium–copper foil stacks to solid tabs. The observations show that pore nucleation, transport, and coalescence are governed by keyhole instability, with defects forming primarily in the trailing melt pool and interacting dynamically with the vapor cavity. Interfacial contact and stack compliance strongly influence defect formation by altering thermal coupling and melt continuity. Unexpectedly, ultrasonic pre-consolidation increases porosity and lack of fusion, whereas unconsolidated stacks achieve better contact and fewer defects, reducing normalized pore counts by up to 25%. These findings identify key factors controlling defect evolution and provide guidance for battery tab joining and related multilayer metallic assemblies. |
| Proceedings Inclusion? |
Planned: |
| Keywords |
Other, Other, Other |