| About this Abstract |
| Meeting |
Materials Science & Technology 2020
|
| Symposium
|
Coating and Thin Film Materials for Energy, Aerospace, Environment and Biological Applications
|
| Presentation Title |
Forming Al Tab to Cu Busbar Joints Using Low Pressure Cold Spray Process |
| Author(s) |
Volf Leshchynsky, Roman Maev, Thomas Brackett, James Boileau, Brian Robert, Emil Strumban |
| On-Site Speaker (Planned) |
Volf Leshchynsky |
| Abstract Scope |
Lithium-ion battery packs are increasingly used in electric vehicles. Each pack consists of modules comprised of a number of pouch cells electrically linked within a module via tab-to-busbar interconnects. Copper is used for busbars, while tabs are often made of thin aluminum foil. Forming mechanically strong, low resistance tab-to-busbar joints of dissimilar metals presents a challenge, since the currently used ultrasonic welding produces brittle intermetallic compounds in the joint interface. Low Pressure Cold Spray (LPCS) is a method allowing for the below melting point material buildup. The main objective of the work was to prove the feasibility of forming LPCS-based Al tab to Cu busbar joints and study their mechanical and microstructural characteristics. Different Al-Zn and Cu-Zn powder composition have been tested. High current resistance of the joints was evaluated. Lap shear tests were performed to establish a correlation between the electrical resistance and the mechanical strength of the joints. |