Welding is the process of joining two pieces of metal together by hammering, pressure or fusion. Filler metal may or may not be used.
Welding is normally done to form a mechanical joint, however, in the field of batteries this is often an electrical joint. Sometimes tested mechanically to ensure that the joint is good.
There are a number of types of welding:
- Ultrasonic
- Laser
- Pulsed Arc or micro-TIG
- Stir
- Resistance
Busbar to Busbar
Weld Mechanical and Electrical Properties: Is there a relationship between weld mechanical and electrical properties? The basic conclusion is that low electrical resistances were found to correlate with high mechanical strengths of the welds.
Busbar to Cell
Cylindrical Cell Joining Methods: Cylindrical cells are commonly joined using several methods, each with distinct advantages and disadvantages depending on the application.
The anti-shunt tab design is there to enable a better resistance micro spot weld. The busbar for a cylindrical or prismatic cell has to be welded blind. Meaning you can only weld from the topside of the busbar as the cell itself is a sealed system.
Cleaning Battery Terminals before Welding – Laser cleaning of terminals is a critical step in the assembly of battery modules. It effectively removes surface impurities and creates optimal conditions for laser welding, which in turn enhances product quality and production yield.
Cell Assembly
Can-Cap Welding of Structural 4680 Aluminium Cell Can To evaluate the weldability of Speira ION Cell 3-CS laser welding trials were conducted at Coherent’s Application Center in Hamburg using the FL8000-ARM 50/200 laser system to identify suitable welding parameters within an industrial relevant setup.
Pack Enclosure
Joining Techniques for Pack Enclosures: there are a lot of “boring” battery topics that often get overlooked and producing the battery housing (sometimes referred to as battery tray or box) is no exception! To house a battery you need a high quality, leak proof container that can easily be produced and today, there is no standard manufacturing method across the industry that solves the challenges in production:
Weld Schedule
The defined set of resistance-welding parameters (current, weld time, electrode force) used to make a consistent, repeatable, high-quality tab-to-cell weld.
We are always wanting to know about the latest in welding techniques and are happy to receive technical posts from companies and research groups on the subject.
See also: Manufacturing – welding and cell joining is one step within the wider module and pack assembly process.