Abstract
The rising demand for high power battery systems for the electric mobility requires the connection of a large number of cells. Due to the functionality of the cell chemistry, a combination of copper and aluminium is necessary. The differing material properties like thermal conductivity as well as the formation of intermetallic phases are challenging for welding processes. This study contains the results for overlap joints of copper and aluminium using a laser beam welding process with spatial power modulation. With a parameter variation, the cross-sectional shape of the weld seams and therefore, the ratio of depth to width can be adjusted. With additional longitudinal cross sections and an energy-dispersive X-ray spectroscopy analysis, the different mixing behaviour of the dissimilar material depending on the top layer is investigated.
Highlights
The worldwide increased attractiveness of electric vehicles leads to rising sales in the last decade [1]
The negative anode is made of thin copper foil, while the positive cathode consists of aluminium
The aim of the study is to determine the influence of the parameters laser power, feed rate and spatial power modulation on the weld seam geometry and mixing behaviour of the dissimilar materials
Summary
The worldwide increased attractiveness of electric vehicles leads to rising sales in the last decade [1]. Most of these cars are using lithium-ion batteries as an energy storage system. The battery cells consist of electrodes with a different electrical load. The negative anode is made of thin copper foil, while the positive cathode consists of aluminium. The electrodes are coated with active materials and separated by an ion permeable membrane. The stacked or rolled electrodes are placed into a housing and filled with electrolyte [2]
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