A multi-physics CFD study on the part-to-part gap during remote laser welding of copper-to-steel battery tab connectors with beam wobbling

Chianese, Giovanni; Jabar, Sharhid; Franciosa, Pasquale; Ceglarek, Dariusz; Patalano, Stanislao

doi:10.1016/j.procir.2022.08.075

Cited by 12 publications

(4 citation statements)

References 9 publications

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“…In this sense, analyses have also been carried out when considering the free surface of the fluid. Chianese et al (2022) presented a 3D numerical study with Flow 3D software. In this way, they analyzed the effect of inter-piece separation on the temperature field and on metal mixing.…”

Section: Frontiers In Mechanical Engineeringmentioning

confidence: 99%

“…The authors concluded that the separation between parts causes uncontrolled mixing of the metal. A year later, Chianese et al (2023) reported the effect of laser beam shaping on metal mixing and molten bath dynamics. The study was performed using Flow 3D software and the multiphysics model considered convection and conduction heat transfer, as well as fluid flow dynamics, and the effect of the square column.…”

Section: Frontiers In Mechanical Engineeringmentioning

confidence: 99%

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Numerical simulations and mathematical models in laser welding: a review based on physics and heat source models

Jiménez-Xamán,

Hernández-Hernández,

Tariq

et al. 2024

Front. Mech. Eng.

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The dominant phenomenon in laser welding processes is heat transfer by conduction, making it crucial to gain insights into energy distribution within the heat-affected region, including the melt pool. Thermal analysis enables the description of thermo-mechanical, metallurgical aspects, and also addresses studies related to fluid flow and energy transfer. As research in welding processes has advanced, these models have evolved. This is why it is now efficient to use computational modeling techniques as it allows us to analyze the behavior of laser welding during the process. This underlines the importance of this work which has carried out an exhaustive theoretical literature review with the objective of classifying and describing the numerical simulations of laser welding based on the physics involved. In that sense, the mathematical models and strategies used in laser welding are explored in a general way. Therefore, two types of laser welding by conduction and deep penetration are defined from this point and they are categorized according to the phenomena involved in Model Heat Conduction and Model Integral Multiphysics. This comprehensive review article serves as a valuable resource for higher education students by providing a structured and detailed exploration of laser welding and its mathematical modeling. By classifying and describing numerical simulations based on the physics involved, it offers a framework for students to understand the complexities of this field. Additionally, this innovative approach to organizing and presenting research contributes to educational innovation by facilitating a more efficient and effective learning experience, helping students acquire the knowledge and research skills necessary for advancements in the laser welding domain.

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Section: Frontiers In Mechanical Engineeringmentioning

confidence: 99%

Section: Frontiers In Mechanical Engineeringmentioning

confidence: 99%

Numerical simulations and mathematical models in laser welding: a review based on physics and heat source models

Jiménez-Xamán,

Hernández-Hernández,

Tariq

et al. 2024

Front. Mech. Eng.

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“…배터리 팩은 e-모빌리티의 핵심 부품으로 배터리 전 기 자동차(Battery Electric Vehicle) 부가가치의 약 40%를 차지하므로, 자동차 제조업체에서는 중요한 개 발 분야이다. 배터리 팩의 대량 생산이 예상됨에 따라 공급업체를 포함한 전체 자동차 시장은 변동성이 큰 시 장 환경과 기밀성 등 다양한 기술 요구 사항을 조화시 켜야 하는 새로운 과제를 안고 있다 [1][2][3][4][5]8,9) . 12) .…”

Section: 서 론unclassified

Review on Recent Laser Welding Trend in Electric Powered Vehicle Production

Choi

2023

J Weld Join

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In this study, we summarize the state-of-the-art laser welding used for welding copper and aluminum alloys, which are key materials for electrified powertrain components. Extensive research on laser beam modulation, power control, beam control, and process monitoring to improve welding reliability and to solve the challenges of dissimilar welds are reviewed and summarized. Furthermore, various techniques for real-time behavior of the weld pool and weld quality monitoring are presented. Along with various techniques to improve spatter and weld pool instability during welding, we have also included research results on process monitoring using artificial intelligence and deep learning techniques. Moreover, computer simulation helps understand various welding phenomena. The research results on improving the quality of welded products through laser beam dynamic control are also included.

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“…Prieto et al and Sun et al also investigated the tailoring of the power distribution for the welding of Al for e-mobility applications [16,17]. Chianese et al explored beam oscillation for the joining of copper to steel joints whilst Rinne et al exploited in-source beam shaping [18,19].…”

Section: Introductionmentioning

confidence: 99%

Effect of in-source beam shaping and laser beam oscillation on the electromechanical properties of Ni-plated steel joints for e-vehicle battery manufacturing

Caprio,

Previtali,

Demir

2023

Journal of Laser Applications

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Laser welding is a key enabling technology that transitions toward electric mobility, producing joints with elevated electrical and mechanical properties. In the production of battery packs, cells to busbar connections are challenging due to strict tolerances and zero-fault policy. Hence, it is of great interest to investigate how beam shaping techniques may be exploited to enhance the electromechanical properties as well as to improve material processability. Industrial laser systems often provide the possibility to oscillate dynamically the beam or redistribute the power in multicore fibers. Although contemporary equipment enables elevated flexibility in terms of power redistribution, further studies are required to indicate the most adequate solution for the production of high performance batteries. Within the present investigation, both in-source beam shaping and beam oscillation techniques have been exploited to perform 0.2–0.2 mm Ni-plated steel welds in lap joint configuration, representative of typical cell to busbar connections. An experimental campaign allowed us to define process feasibility conditions where partial penetration welds could be achieved by means of in-source beam shaping. Hence, beam oscillation was explored to perform the connections. In the subset of feasible conditions, the mechanical strength was determined via tensile tests alongside electrical resistance measurements. Linear welds with a Gaussian beam profile enabled joints with the highest productivity at constant electromechanical properties. Spatter formation due to keyhole instabilities could be avoided by redistributing the emission power via multicore fibers, while dynamic oscillation did not provide significant benefits.

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A multi-physics CFD study on the part-to-part gap during remote laser welding of copper-to-steel battery tab connectors with beam wobbling

Cited by 12 publications

References 9 publications

Numerical simulations and mathematical models in laser welding: a review based on physics and heat source models

Numerical simulations and mathematical models in laser welding: a review based on physics and heat source models

Review on Recent Laser Welding Trend in Electric Powered Vehicle Production

Effect of in-source beam shaping and laser beam oscillation on the electromechanical properties of Ni-plated steel joints for e-vehicle battery manufacturing

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