Welding techniques for battery cells and resulting electrical contact resistances

Brand, Martin J.; Schmidt, Philipp; Zaeh, Michael F.; Jossen, Andreas

doi:10.1016/j.est.2015.04.001

Cited by 172 publications

(102 citation statements)

References 22 publications

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“…The measurement procedure to determine the ECR is the following: Welding high mechanical strength high speed process [1] heat input [3] hard to produce a large joint area [1] difficult for highly conductive materials [1] non-separable joint Clamped no heat input separable joint simple joining of different materials additional parts and mass [1] labor-intensive [1] mechanical stress limits the range of applicable cells 3 After the measurement at 400 N, the screw is loosed and the conductor is taken from the positive terminal.…”

Section: Measurement Procedures For Determining the Electrical Contactmentioning

confidence: 99%

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Electrical contact resistance measurements of clamped battery cell connectors for cylindrical 18650 battery cells

Bolsinger

Zorn

Birke

2017

Journal of Energy Storage

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Section: Measurement Procedures For Determining the Electrical Contactmentioning

confidence: 99%

“…They show that the ECR can be reduced to a value of about 10 mV by applying a sufficient force on the contact. The works of Brand et al and Schmidt et al, show the measurement of the electrical contact resistance for welded cell connections [3,4]. Laser beam welding achieves the lowest ECR of about 130 mV.…”

Section: Introductionmentioning

confidence: 98%

Electrical contact resistance measurements of clamped battery cell connectors for cylindrical 18650 battery cells

Bolsinger

Zorn

Birke

2017

Journal of Energy Storage

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“…Resistance spot welding (RSW) works on the principle of electrical resistance at the mating surfaces creating localised heating and fusion of materials under pressure when a high current passes through them [20][21][22]. Figure 4 provides a schematic illustration of resistance spot welding used for tab welding.…”

Section: Overview Of Joining Methodsmentioning

confidence: 99%

Weldability and shear strength feasibility study for automotive electric vehicle battery tab interconnects

Das

Williams

et al. 2019

J Braz. Soc. Mech. Sci. Eng.

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Lithium-ion-based secondary battery packs are emerging as an alternative power source and are being increasingly used in electric vehicles, hybrid or plug-in hybrid electric vehicles. Typically, a standard automotive battery pack consists of hundreds, even thousands, of individual cells which are connected in series and/or parallel to deliver the required power and capacity. There is an increasing need for manufacturing of battery packs to meet the demand reflecting the uptake of these vehicles. This triggers the need for suitable joining methods which will provide mechanical strength on a par with electrical and thermal characteristics. This work focuses on characterisation of shear strength of battery tab-to-tab joints for both similar and dissimilar materials by using combinations of aluminium (Al) and nickel-coated copper (Cu[Ni]) tabs. The joining techniques with application for battery tab interconnects are ultrasonic metal welding, resistance spot welding and pulsed TIG spot welding. Lap shear and T-peel tests are performed to evaluate the joint strength. In general, lap shear strength is four to seven times higher than the T-peel strength obtained from all three joining methods. In addition, an indicator is developed in this paper based on lap shear-to-T-peel strength reduction ratio which provides additional information on joint strength characteristics, and subsequently, it can be used as a threshold by quality engineers for an indication on selection of joining methods having an acceptable strength reduction ratio.

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“…The joining of dissimilar Al and Cu is a promising technology for Li-ion batteries electrodes due to the contactless power delivery and low-inertia positioning system. In a comparative study, it was found that the mechanical strength and electrical conductivity are highest for laser-welded battery cells compared to resistance and ultrasonic welding [1]. The laser joining of dissimilar material is performed by selectively melting only one of the joining partners, thus controlling the intermixture.…”

Section: Introductionmentioning

confidence: 99%

Metallographic Studies of Dissimilar Al-Cu Laser-Welded Joints Using Various Etchants

Schmalen

Mathivanan

Plapper

2018

Metallogr. Microstruct. Anal.

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The welding of Al and Cu is considered as difficult due to the formation of intermetallic compounds, which cause a brittle joint with increased electrical resistance. This paper investigates etching techniques that were used to contrast the intermetallic compounds for optical microscope analysis. A 0.5 mm AA-1050 sheet was welded to a 0.5 mm SF-Cu sheet in overlap configuration. The cross sections were etched by using 17 different reagents, including common Al-grade 2xxx etchants, Al-bronze etchants, and specific IMC etchants. A complete microstructural characterization, including the formation of intermetallic compounds, is presented. The experimental result showed that a clear distinction of metallurgic structures is possible, thus enabling a more detailed analysis of Al-Cu welds. It was found that etchants #09, #14, and #16 revealed best the four different intermetallic compounds θ-

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Welding techniques for battery cells and resulting electrical contact resistances

Cited by 172 publications

References 22 publications

Electrical contact resistance measurements of clamped battery cell connectors for cylindrical 18650 battery cells

Electrical contact resistance measurements of clamped battery cell connectors for cylindrical 18650 battery cells

Weldability and shear strength feasibility study for automotive electric vehicle battery tab interconnects

Metallographic Studies of Dissimilar Al-Cu Laser-Welded Joints Using Various Etchants

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