Blue laser welding of low thickness Ni-coated copper and mild steel for electric vehicle (EV) battery manufacturing

Sadeghian, Amirhossein; Iqbal, Naveed

doi:10.1016/j.optlastec.2022.108415

Cited by 24 publications

(7 citation statements)

References 26 publications

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“…The combination of ductile and brittle intermetallic microstructure was found, resulting in a strong joint with large plastic deformation of the aluminum sheet [ 49 ]. The authors in [ 50 ] focused on conduction mode welding using a blue laser for welding low-thickness dissimilar materials, namely nickel-coated copper and mild steel, for electric vehicle battery manufacturing. Ascari et al also welded 0.3 mm thick nickel-plated copper sheets to 0.4 mm thick aluminum sheets by using a 450 nm diode laser, finding a smooth seam with no cracks or pores in the weld.…”

Section: State Of the Artmentioning

confidence: 99%

“…From the state -of -the -art and the amount of research on this topic, it can be concluded that a deeper understanding of the influencing factors affecting the welding process is absolutely needed and the top plate configuration selection in copper aluminum joining requires methodology. In summary, only limited research has been conducted to study copper as top plate in copper aluminum mixed joints [ 49 ], as for example the investigations in [ 50 , 51 , 52 ]. In addition, the use of visible laser radiation proves high potential for these limited material thicknesses in deep penetration mode to create a reproducible, low fluctuation joint between the two metals.…”

Section: State Of the Artmentioning

confidence: 99%

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Seam Properties of Overlap Welding Strategies from Copper to Aluminum Using Green Laser Radiation for Battery Tab Connections in Electric Vehicles

et al. 2023

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Laser beam welding of metals has progressed dramatically over the last years mainly arising from joining applications in the field of electromobility. Allowing the flexible, automated manufacturing of mechanically, electrically, and thermally stressed components, the process is more frequently applied for joining highly reflective materials, for example for battery tab and busbar connections. The local, non-contact energy input favors this welding technology; however, joining of copper and aluminum sheets still poses a challenge due to the physical properties of the joining partners and intermetallic phases from dissimilar metal interaction, which reduce seam performance. The use of green laser radiation compared to infrared laser radiation offers the advantage of a significantly increased absorptivity for copper materials. A changed incoupling behavior is observed, and a lower deep penetration threshold has been already proven for 515 nm wavelength. When copper and aluminum are welded with the former as top sheet, this welding mode is essential to overcome limited aspect ratios from heat conduction welding. However, the opportunities of applying these beam sources in combination with spatial power modulation to influence the interconnection area of copper-aluminum joints have not yet been studied. The aim of this work is therefore to investigate the seam properties and process stability of different overlap welding strategies using green laser radiation for dissimilar metal welding. A microstructural analysis of the different fusion zones and mechanical strength of the joints are presented. In addition, the experimental parameter sets were analyzed regarding their application in battery module busbars by examining the electrical resistance and temperature distribution after welding. A parameter window was identified for all investigated welding strategies, with the stitched seam achieving the most stable results.

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Section: State Of the Artmentioning

confidence: 99%

Section: State Of the Artmentioning

confidence: 99%

Seam Properties of Overlap Welding Strategies from Copper to Aluminum Using Green Laser Radiation for Battery Tab Connections in Electric Vehicles

et al. 2023

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“…In addition, laser welding has the problem of welding defects due to the small spot size and high power of the processing point. Therefore, welding using lasers in the visible light wavelength region, which have high optical absorption for copper and aluminum, has been actively studied [3][4][5]. Furthermore, assist gas is used as one of the solutions to improve welding quality by eliminating such welding defects and achieving stable welding [6,7].…”

Section: Introductionmentioning

confidence: 99%

Influence of flow rate and gas type with a novel nozzle capable of simultaneously gas flow and suction on weld quality in laser welding

Koba,

Kikuchi,

Nakamura

et al. 2024

High-Power Laser Materials Processing: Applications, Diagnostics, and Systems XIII

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Laser welding has been actively used in automotive manufacturing and other fields because of its non-contact and easy operation. In particular, the demand for high-quality welding of copper and aluminum is increasing due to the growing popularity of electric vehicles. However, conventional laser welding has led to problems such as spatter and unstable weld beads. Assist gas is one solution to improve welding efficiency and stabilize weld quality. In this study, two new nozzles for laser head scanning and Galvano scanning were developed that can simultaneously flow and suction gas to the laser welding area. In butt welding of steel using an infrared laser, fume removal from the laser optical axis and elimination of undercuts were achieved by airflow through the nozzles. In spot irradiation of copper using a blue laser, it was confirmed that fumes could be controlled by airflow and that the gas flow and suction by the nozzle produced differences in oxygen content at different processing positions.

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“…For example, copper and gold metals possess a lower reflectance in the VIS than in the IR and therefore can be better fine-processed with blue laser diodes. 14,15 The renewed demand for high-performance OIs for the UV-VIS wavelength regions has boosted the development and implementation of CeF 3 single crystals as FRs in recent years. [16][17][18][19] This compound was intensively investigated as a scintillator in the past, [20][21][22] and here a comprehensive review of the advantageous physical and chemical properties for magneto-optical applications is presented.…”

Section: Introductionmentioning

confidence: 99%

“…Nowadays, there is an emerging market for laser technologies at shorter wavelengths that goes beyond the former R&D use: new applications in the fields of manufacturing, medicine, etc., that require high precision at smaller scales, and/or make use of specific UV‐VIS absorption wavelengths of matter. For example, copper and gold metals possess a lower reflectance in the VIS than in the IR and therefore can be better fine‐processed with blue laser diodes 14,15 . The renewed demand for high‐performance OIs for the UV‐VIS wavelength regions has boosted the development and implementation of CeF 3 single crystals as FRs in recent years 16–19 .…”

Section: Introductionmentioning

confidence: 99%

CeF₃ single crystals for UV‐VIS‐IR optical isolators

Vı́llora

Yuan

Shimamura

2023

Int J Applied Ceramic Tech

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Optical isolators (OIs) are needed to protect laser sources from back‐reflections. Driven by the fast‐growing market of laser marking and machinery, and the increasing cost of rare‐earth‐based permanent magnets, single‐crystalline Faraday rotators (FRs) with a large Verdet constant V are highly desired to reduce the cost and size of OIs. Furthermore, the need for finer laser procedures (marking, cutting, welding) is shifting the used laser emissions toward shorter wavelengths: into the visible (VIS), where standard Tb3Ga5O12 (TGG) has a poor transmittance, and even into the ultraviolet (UV), where TGG possesses overlapping Tb 4f‐4f absorption bands. In recent years CeF3 has emerged as a new FR with a unique transmittance and an outstanding V in the UV wavelength region, and a superior figure‐of‐merit in the VIS range compared to TGG. Recently, its small thermal lensing and high damage threshold for high‐power have been demonstrated, exhibiting optical isolation > 30 dB under 600 W @ 1070 nm. This review first summarizes the basic properties and crystal growth of CeF3, then focuses on its Faraday magneto‐optical performance. Last but not the least, the typical crystal defects encountered during the development of CeF3 are discussed.

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Blue laser welding of low thickness Ni-coated copper and mild steel for electric vehicle (EV) battery manufacturing

Cited by 24 publications

References 26 publications

Seam Properties of Overlap Welding Strategies from Copper to Aluminum Using Green Laser Radiation for Battery Tab Connections in Electric Vehicles

Seam Properties of Overlap Welding Strategies from Copper to Aluminum Using Green Laser Radiation for Battery Tab Connections in Electric Vehicles

Influence of flow rate and gas type with a novel nozzle capable of simultaneously gas flow and suction on weld quality in laser welding

CeF₃ single crystals for UV‐VIS‐IR optical isolators

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Blue laser welding of low thickness Ni-coated copper and mild steel for electric vehicle (EV) battery manufacturing

Cited by 24 publications

References 26 publications

Seam Properties of Overlap Welding Strategies from Copper to Aluminum Using Green Laser Radiation for Battery Tab Connections in Electric Vehicles

Seam Properties of Overlap Welding Strategies from Copper to Aluminum Using Green Laser Radiation for Battery Tab Connections in Electric Vehicles

Influence of flow rate and gas type with a novel nozzle capable of simultaneously gas flow and suction on weld quality in laser welding

CeF3 single crystals for UV‐VIS‐IR optical isolators

Contact Info

Product

Resources

About

CeF₃ single crystals for UV‐VIS‐IR optical isolators