Parametric Study of Pulse Arc Welding (PAW) and Laser Beam Welding (LBW) Techniques for Electrical Vehicle Battery Cells

2021 ◽  
Vol 1016 ◽  
pp. 611-617
Author(s):  
Naveed Iqbal ◽  
Subhasisa Nath ◽  
Alison E. Coleman ◽  
Jonathan Lawrence
Keyword(s):  
Tensile Strength ◽  
Laser Beam ◽  
Parametric Study ◽  
Arc Welding ◽  
Mechanical Performance ◽  
Laser Beam Welding ◽  
Dissimilar Materials ◽  
Pulsed Arc Welding ◽  
Battery Systems ◽  
Battery Cells

Electrical vehicles (EV) offer the automotive industry the potential to meet future emission targets by developing large battery systems. These battery systems require several thousand single battery cells to be connected together. The battery cells are complex assemblies of dissimilar materials with very low thicknesses, which presents a significant challenge during the joining process, especially welding. We have investigated the performance of laser beam welding (LBW), as well as pulsed arc welding (PAW) for joining 0.3mm thickness nickel coated copper to 0.7mm thickness mild steel. The parametric study for good quality lap welds based on high tensile strength, was performed. The weld microstructure was investigated using optical, as well as scanning electron microscopy (SEM). The mechanical performance of the weld samples was characterized through tensile testing and micro hardness measurements to establish the microstructure property relationship. The maximum tensile strength measured for specified weld geometries was 660N for LBW and 496N for PAW. A significant increase in the hardness was measured in the weld nugget due to the formation of Cu-Fe composite microstructure

scholarly journals Hybrid laser-arc welding of laser- and plasma-cut 20-mm-thick structural steels

2022 ◽  
Author(s):  
Ömer Üstündağ ◽  
Nasim Bakir ◽  
Sergej Gook ◽  
Andrey Gumenyuk ◽  
Michael Rethmeier
Keyword(s):  
Laser Beam ◽  
Arc Welding ◽  
Laser Beam Welding ◽  
Digital Camera ◽  
Welding Process ◽  
Beam Power ◽  
Beam Diameter ◽  
Hybrid Laser Arc Welding ◽  
Single Pass ◽  
New Findings

AbstractIt is already known that the laser beam welding (LBW) or hybrid laser-arc welding (HLAW) processes are sensitive to manufacturing tolerances such as gaps and misalignment of the edges, especially at welding of thick-walled steels due to its narrow beam diameter. Therefore, the joining parts preferably have to be milled. The study deals with the influence of the edge quality, the gap and the misalignment of edges on the weld seam quality of hybrid laser-arc welded 20-mm-thick structural steel plates which were prepared by laser and plasma cutting. Single-pass welds were conducted in butt joint configuration. An AC magnet was used as a contactless backing. It was positioned under the workpiece during the welding process to prevent sagging. The profile of the edges and the gap between the workpieces were measured before welding by a profile scanner or a digital camera, respectively. With a laser beam power of just 13.7 kW, the single-pass welds could be performed. A gap bridgeability up to 1 mm at laser-cut and 2 mm at plasma-cut samples could be reached respectively. Furthermore, a misalignment of the edges up to 2 mm could be welded in a single pass. The new findings may eliminate the need for cost and time-consuming preparation of the edges.

Comparative Study on Pulsed Laser Welding Strategies for Contacting Lithium-Ion Batteries

2016 ◽  
Vol 1140 ◽  
pp. 312-319 ◽  
Author(s):  
Patrick Schmitz
Keyword(s):  
Laser Beam ◽  
Comparative Study ◽  
Weld Seam ◽  
Laser Beam Welding ◽  
Pulsed Laser ◽  
Pulsed Laser Beam Welding ◽  
Joining Process ◽  
Suitable Process ◽  
Pulsed Laser Beam ◽  
Battery Cells

The transition towards renewable energy implicates more decentralized and time-dependent ways of energy generation. In order to deal with the resulting fluctuation in energy supply, local storage systems are necessary. Larger systems may consist of thousands of battery cells. Therefore, the reliable interconnection between the individual battery cells is the basic prerequisite for the production of these systems. It has been demonstrated that laser beam welding is a suitable process for the contacting of batteries. However, due to the high requirements regarding the heat input and the reproducibility of the joining process, further investigations are necessary. Within this work, experiments on pulsed laser beam welding of nickel-plated DC04 steel were conducted. Four different pulsed welding strategies were analyzed in a preliminary study in order to develop a method for obtaining suitable process parameters while reducing the amount of free parameters. Subsequently, a comparative study between the rectangular pulse, the shaped pulse, the spike pulse and the sloping pulse was carried out. The weld seam properties as well as the electrical and the mechanical properties of the connection joints were evaluated. The results presented in this paper indicate a high eligibility of pulsed laser beam welding as a joining process for the connection of battery cells. For all analyzed pulsed welding strategies a homogeneous weld seam without full penetration was observed. Similar electrical resistances for all strategies were measured despite the comparatively small total joint area for the discretely pulsed weld seams.

scholarly journals Laser Beam Welding with High-Frequency Beam Oscillation: Welding of Dissimilar Materials with Brilliant Fiber Lasers

2011 ◽  
Vol 12 ◽  
pp. 142-149 ◽  
Author(s):  
Mathias Kraetzsch ◽  
Jens Standfuss ◽  
Annett Klotzbach ◽  
Joerg Kaspar ◽  
Berndt Brenner ◽  
...  
Keyword(s):  
Laser Beam ◽  
High Frequency ◽  
Fiber Lasers ◽  
Laser Beam Welding ◽  
Dissimilar Materials ◽  
Beam Oscillation

scholarly journals Enhanced mechanical performance of fusion zone in laser beam welding joint of molybdenum alloy due to solid carburizing

2019 ◽  
Vol 181 ◽  
pp. 107957 ◽  
Author(s):  
Liang-Liang Zhang ◽  
Lin-Jie Zhang ◽  
Jian Long ◽  
Xu Sun ◽  
Jian-Xun Zhang ◽  
...  
Keyword(s):  
Laser Beam ◽  
Fusion Zone ◽  
Mechanical Performance ◽  
Laser Beam Welding ◽  
Molybdenum Alloy ◽  
Welding Joint

Evaluation of High Penetration Hybrid Laser-GMAW Welding Process Productivity Applied in the Joining of Thick Plates and Pipelines

2022 ◽  
Author(s):  
Rafael Gomes Nunes Silva ◽  
Max Baranenko Rodrigues ◽  
Milton Pereira ◽  
Koen Faes
Keyword(s):  
Laser Beam ◽  
Arc Welding ◽  
Manufacturing Industry ◽  
Operating Time ◽  
Laser Beam Welding ◽  
Welding Process ◽  
Major Influence ◽  
Thick Plates ◽  
High Penetration ◽  
Welding Processes

Abstract Welding processes are present in all sectors of the industry, highlighting the manufacturing industry of thick plates and pipelines. In these applications, welding processes have a major influence on costs, schedules, risk analysis and project feasibility. Conventional arc welding processes, such as the gas metal arc welding (GMAW) process, have limitations when applied to high thickness joints due to their maximum achievable penetration depth. On the other hand, the laser beam welding (LBW) welding process, despite reaching high penetration depths, has several limitations mainly regarding the geometric tolerance of the joint. In this regard, the hybrid laser-arc welding (HLAW) process emerges as a promising bonding process, combining the advantages of the GMAW and LBW processes into a single melting pool. Despite the many operational and metallurgical advantages, the HLAW process presents a high complexity due to the high number of parameters involved and the interaction between the laser beam and the electric arc. The present work discusses the challenges involved in the parametrization of the HLAW process applied to the joining of thick plates and pipes, and empirically evaluated a comparison between the HLAW and GMAW processes, showing a reduction of operating time of approximately 40 times, and a reduction of consumption of shielding gas and filler material of approximately 20 times, evidencing the technical and financial contribution of the hybrid process.

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