A Study on Electrical and Electrochemical Characteristics of Friction Stir Welded Lithium-Ion Battery Tabs for Electric Vehicles

A review on dissimilar laser welding of steel-copper, steel-aluminum, aluminum-copper, and steel-nickel for electric vehicle battery manufacturing

“…Each of these techniques has its advantages and limitations and is used based on cell type, properties, and thickness of the materials involved [20]. Other joining processes such as soldering, friction stir welding, micro-TIG or pulsed arc welding, joining by forming, and adhesive bonding have also been proposed [34][35][36][37][38]. However, due to the lack of information at present, further research is needed to thoroughly investigate their feasibility [21].…”

Industry 4.0 Application in Manufacturing for Real-Time Monitoring and Control

“…This fuses the materials and a weld joint is formed. Because FSW does not melt the basematerials, it is recommended for softalloys such as aluminum, magnesium, and the like materials in both similar and dissimilar configurations [7][8][9][10]. This welding process has multiple applications in shipbuilding, railways, aerospace,and automobile sectors.…”

Molecular dynamics simulation of atomic diffusion in friction stir spot welded Al to Cu joints

“…The friction stir spot welding (FSSW) has recently gained significant importance in overlap joining of dissimilar materials 1,2 , which is a variant of solid state friction stir welding (FSW) originally developed for difficult to fusion weld materials such as Al-alloys [3][4][5][6][7][8] . Among such, aluminum (Al) and copper (Cu) welded joints have potential applications in battery pack fabrication 9 . The current collectors (tabs) of the Li-ion battery are welded to make a series and parallel combinations 9 .…”

“…Among such, aluminum (Al) and copper (Cu) welded joints have potential applications in battery pack fabrication 9 . The current collectors (tabs) of the Li-ion battery are welded to make a series and parallel combinations 9 . The higher conductive properties of Al and Cu needed an optimum process condition to generate a sufficient amount of heat to plasticise the weld materials for good quality welds.…”

“…Here, the short-circuit diffusion in the dissimilar materials enhances the intermetallic compound (IMC) formation at the weld interface 13,14 . The atomic interdiffusion by the solidstate leads to the formation of epitaxial Al-rich (Al2Cu [002]) and Cu-rich (Al4Cu9 [113]) IMC 9,15 . The molecular dynamics simulation (MD) is an effective method to investigate this microscopic phenomenon like diffusion and IMC formation in a system that is placed under given process conditions 16 .…”