| About this Abstract |
| Meeting |
2023 AWS Professional Program
|
| Symposium
|
2023 AWS Professional Program
|
| Presentation Title |
Laser Welding of Al-Cu Interconnects for E-Mobility Applications: Effect of Beam Oscillation on Metal Mixing, Microstructure, and Mechanical Property |
| Author(s) |
Wenda Tan |
| On-Site Speaker (Planned) |
Wenda Tan |
| Abstract Scope |
The main trend in automotive industry is the rapid shift from internal combustion engines (ICEs) to electric vehicles (EVs). The battery tab to busbar connection is one of the important joints in the assembly of battery pack for EVs. Aluminum (Al) and copper (Cu) are the most common materials used in battery tabs and busbars. Therefore, the joining of dissimilar Al-Cu is inevitable in designed architectures for pouch battery modules and pack assemblies. Remote laser welding due to its advantages is the main choice of joining technology in EV applications. However, laser welding of Al-Cu is challenging and dissimilar metal mixing in the molten pool often causes the formation of intermetallic compounds that can undermine the performance of the welded joints.
In this presentation, the metal mixing process in line-scan and oscillating laser keyhole welding of dissimilar metals will be discussed in-depth through the experimental and numerical findings. Results have shown the advantage of laser beam oscillation in improving joint performance. The underlying physics of the process-microstructure-property relationship will be discussed for the laser welding of Al-Cu in battery cell and module manufacturing applications. The developed simulation framework will reveal the effects of laser oscillation parameters on fluid flow, metal mixing, and phase formation of the welds. All results providing valuable information can be utilized in the design and process optimization of the dissimilar welding process to obtain reliable welds. |
| Proceedings Inclusion? |
Undecided |