Impact of ultrasonic welding on multi-layered Al–Cu joint for electric vehicle battery applications: A layer-wise microstructural analysis

Abstract

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Understanding novel gap-bridged remote laser welded (RLW) joints for automotive high-rate and temperature applications

“…Additionally, slight microhardness fluctuation was observed within the base material before entering the fusion zone and after leaving the fusion zone in the first few millimetres and is possibly due to exposure to elevated heat during the welding, release of internal stresses and thermal softening [55][56][57]. As a result, over ageing took place during welding which is common for 6xxx series aluminium alloys [37].…”

Blue laser welding of multi-layered AISI 316L stainless steel micro-foils

“…At present, various joining techniques are used to weld batteries or supercapacitors including ultrasonic welding, ultrasonic wedge bonding, pulsed TIG spot welding, resistance spot/projection welding, micro-clinching, soldering, laser welding and mechanical assembly [12][13][14]. For multiple sheet welding of soft materials, ultrasonic welding is preferred and used for welding tabs/busbars made of copper, aluminium or nickel [15,16]. However, traditional joining methods, such as mechanical or ultrasonic bonding, are no longer adequate for the higher power demands of modern batteries which require the use of harder materials like stainless steel.…”

An experimental and numerical investigation on impact spot welding of metallic plates using gas mixture detonation technique

“…34 In this situation, the equivalent plastic failure strain value e pl f severely relies on the element characteristic length L due to strain localization and it cannot be employed as a material parameter to define the damage evolution law. Therefore, the damage evolution law is defined by the following relationship in terms of the equivalent plastic displacement u pl34 u pl ¼ L e pl À e pl D (5) where L depends on the element geometry and it is considered as the cube root of the integration point volume in the present study. The equivalent plastic displacement takes into account the element characteristic length to diminish mesh dependency of the results at strain localization.…”

“…Therefore, solid-state welding processes are a reliable alternative for bonding nonhomogeneous materials since there is no need for extensive melting of materials to bond. Recently, various solid-state welding methods such as magnetic pulse welding, 1,2 laser impact welding, 3,4 ultrasonic welding, 5,6 resistance welding, 7,8 friction stir welding, 9,10 explosive welding, 11,12 and projectile impact spot welding [13][14][15] have made significant progress. Among these mentioned processes, explosive welding, magnetic pulse welding, laser impact welding, and projectile impact spot welding can be considered as the high-speed impact welding technique.…”