A novel integrated process-performance model for laser welding of multi-layer battery foils and tabs

Kamat, Sudhan A.; Cai, Wayne; Rinker, Teresa J.; Bracey, Jennifer; Liang, Xi; Tan, Wenda

doi:10.1016/j.jmatprotec.2023.118121

Cited by 6 publications

(2 citation statements)

References 36 publications

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“…In the experimental results, they found that the porosity can be reduced by combining a heat source with an annular laser beam and a source with a Gaussian beam. The case study presented by Kamat et al (2023) developed a multiphysics model integrated into the process of laser welding of thin films. The model considered evaporation, the VOF method, weld puddle dynamics, in-pool absorption, and multiple reflection.…”

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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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%

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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“…There are fewer modelling approaches for battery LW applications or for dissimilar metal welding. In a recent approach [71] by combining computational fluid dynamics and finite element analysis process simulation in the T2T welding of thin Cu sheets, the authors were able to predict the weld bead dimension with high accuracy and also predict the mechanical properties such as the failure point and the force-displacement curves of shear tests. To investigate the effect of joint size and shape on the electrical resistance of the joint, the authors in [72] developed a multi-physics simulation model.…”

Section: Laser Weldingmentioning

confidence: 99%

Welding Challenges and Quality Assurance in Electric Vehicle Battery Pack Manufacturing

Stavropoulos,

Sabatakakis,

Bikas

2024

Batteries

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Electric vehicles’ batteries, referred to as Battery Packs (BPs), are composed of interconnected battery cells and modules. The utilisation of different materials, configurations, and welding processes forms a plethora of different applications. This level of diversity along with the low maturity of welding designs and the lack of standardisation result in great variations in the mechanical and electrical quality of the joints. Moreover, the high-volume production requirements, meaning the high number of joints per module/BP, increase the absolute number of defects. The first part of this study focuses on associating the challenges of welding application in battery assembly with the key performance indicators of the joints. The second part reviews the existing methods for quality assurance which concerns the joining of battery cells and busbars. Additionally, the second part of this paper identifies the general trends and the research gaps for the most widely adopted welding methods in this domain, while it renders the future directions.

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Orthogonal experiments and bonding analysis of ultrasonic welded multi-layer battery foils and tabs

Zhao,

Su,

et al. 2024

Engineering Science and Technology, an International Journal

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A novel integrated process-performance model for laser welding of multi-layer battery foils and tabs

Cited by 6 publications

References 36 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

Welding Challenges and Quality Assurance in Electric Vehicle Battery Pack Manufacturing

Orthogonal experiments and bonding analysis of ultrasonic welded multi-layer battery foils and tabs

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