About this Abstract |
| Meeting |
2026 TMS Annual Meeting & Exhibition
|
| Symposium
|
Forming and Joining of Advanced Sheet Metal Materials
|
| Presentation Title |
Jetting–Oxide-Intermetallic Coupling and Electrical Performance of Al-Cu and Al-Cu-Cu Busbar Joints in VFAW |
| Author(s) |
Deepak Kumar, Jungyu Choi , Taeseon Lee |
| On-Site Speaker (Planned) |
Deepak Kumar |
| Abstract Scope |
High-speed Vaporizing Foil Actuator Welding (VFAW) is promising for aluminum–copper busbar joining in EV batteries, yet electrical performance is hindered by jet-induced oxide entrainment and intermetallic growth. This study employs full-scale smoothed particle hydrodynamics (SPH) simulations to predict jetting onset, angle, and extent in Al–Cu and Al-Cu-Cu stack-ups, linking these to weldability length ratio (WLR) and electrical conductivity. Predicted thermal and jetting fields are validated via SEM/EDS of welded interfaces and correlated with tensile shear strength and four-point probe conductivity measurements. Results reveal that excessive jetting increases oxide content and localized intermetallic phases, reducing conductivity despite apparent mechanical bonding. A physics-based criterion is proposed to optimize discharge energy and standoff to balance joint strength and electrical efficiency. This framework establishes the first direct jetting-electrical linkage in VFAW, offering design guidance for multi-layer busbar manufacturing in next-generation electric vehicles. |
| Proceedings Inclusion? |
Planned: |
| Keywords |
Modeling and Simulation, Aluminum, Joining |