Parametric Study of Pulse Arc Welding (PAW) and Laser Beam Welding (LBW) Techniques for Electrical Vehicle Battery Cells

Naveed Iqbal; Subhasisa Nath; Alison E. Coleman; Jonathan Lawrence

doi:10.4028/www.scientific.net/MSF.1016.611

Parametric Study of Pulse Arc Welding (PAW) and Laser Beam Welding (LBW) Techniques for Electrical Vehicle Battery Cells

Naveed Iqbal, Subhasisa Nath, Alison E. Coleman, Jonathan Lawrence

Research output: Contribution to journal › Article › peer-review

6 Citations (Scopus)

Abstract

Electrical vehicles (EV) offer the automotive industry the potential to meet future emission targets by developing large battery systems. These battery systems require several thousand single battery cells to be connected together. The battery cells are complex assemblies of dissimilar materials with very low thicknesses, which presents a significant challenge during the joining process, especially welding. We have investigated the performance of laser beam welding (LBW), as well as pulsed arc welding (PAW) for joining 0.3mm thickness nickel coated copper to 0.7mm thickness mild steel. The parametric study for good quality lap welds based on high tensile strength, was performed. The weld microstructure was investigated using optical, as well as scanning electron microscopy (SEM). The mechanical performance of the weld samples was characterized through tensile testing and micro hardness measurements to establish the microstructure property relationship. The maximum tensile strength measured for specified weld geometries was 660N for LBW and 496N for PAW. A significant increase in the hardness was measured in the weld nugget due to the formation of Cu-Fe composite microstructure

Original language	English
Pages (from-to)	611-617
Number of pages	7
Journal	Materials Science Forum
Volume	1016
Early online date	5 Jan 2021
DOIs	https://doi.org/10.4028/www.scientific.net/MSF.1016.611
Publication status	E-pub ahead of print - 5 Jan 2021

Bibliographical note

Authors may also deposit in a closed access institutional repository, "The amount of information self-archived by authors in open access institutional repositories or public servers should not exceed the amount of information freely available on www.scientific.net website for unregistered users

Funder

Innovate UK APC12 H1perChain project.

Keywords

Copper
Electrical vehicle battery
Laser beam welding
Pulse arc welding
Steel

ASJC Scopus subject areas

Materials Science(all)
Condensed Matter Physics
Mechanics of Materials
Mechanical Engineering

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title = "Parametric Study of Pulse Arc Welding (PAW) and Laser Beam Welding (LBW) Techniques for Electrical Vehicle Battery Cells",

abstract = "Electrical vehicles (EV) offer the automotive industry the potential to meet future emission targets by developing large battery systems. These battery systems require several thousand single battery cells to be connected together. The battery cells are complex assemblies of dissimilar materials with very low thicknesses, which presents a significant challenge during the joining process, especially welding. We have investigated the performance of laser beam welding (LBW), as well as pulsed arc welding (PAW) for joining 0.3mm thickness nickel coated copper to 0.7mm thickness mild steel. The parametric study for good quality lap welds based on high tensile strength, was performed. The weld microstructure was investigated using optical, as well as scanning electron microscopy (SEM). The mechanical performance of the weld samples was characterized through tensile testing and micro hardness measurements to establish the microstructure property relationship. The maximum tensile strength measured for specified weld geometries was 660N for LBW and 496N for PAW. A significant increase in the hardness was measured in the weld nugget due to the formation of Cu-Fe composite microstructure",

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AU - Nath, Subhasisa

AU - Coleman, Alison E.

AU - Lawrence, Jonathan

N1 - Authors may also deposit in a closed access institutional repository, "The amount of information self-archived by authors in open access institutional repositories or public servers should not exceed the amount of information freely available on www.scientific.net website for unregistered users

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N2 - Electrical vehicles (EV) offer the automotive industry the potential to meet future emission targets by developing large battery systems. These battery systems require several thousand single battery cells to be connected together. The battery cells are complex assemblies of dissimilar materials with very low thicknesses, which presents a significant challenge during the joining process, especially welding. We have investigated the performance of laser beam welding (LBW), as well as pulsed arc welding (PAW) for joining 0.3mm thickness nickel coated copper to 0.7mm thickness mild steel. The parametric study for good quality lap welds based on high tensile strength, was performed. The weld microstructure was investigated using optical, as well as scanning electron microscopy (SEM). The mechanical performance of the weld samples was characterized through tensile testing and micro hardness measurements to establish the microstructure property relationship. The maximum tensile strength measured for specified weld geometries was 660N for LBW and 496N for PAW. A significant increase in the hardness was measured in the weld nugget due to the formation of Cu-Fe composite microstructure

AB - Electrical vehicles (EV) offer the automotive industry the potential to meet future emission targets by developing large battery systems. These battery systems require several thousand single battery cells to be connected together. The battery cells are complex assemblies of dissimilar materials with very low thicknesses, which presents a significant challenge during the joining process, especially welding. We have investigated the performance of laser beam welding (LBW), as well as pulsed arc welding (PAW) for joining 0.3mm thickness nickel coated copper to 0.7mm thickness mild steel. The parametric study for good quality lap welds based on high tensile strength, was performed. The weld microstructure was investigated using optical, as well as scanning electron microscopy (SEM). The mechanical performance of the weld samples was characterized through tensile testing and micro hardness measurements to establish the microstructure property relationship. The maximum tensile strength measured for specified weld geometries was 660N for LBW and 496N for PAW. A significant increase in the hardness was measured in the weld nugget due to the formation of Cu-Fe composite microstructure

KW - Copper

KW - Electrical vehicle battery

KW - Laser beam welding

KW - Pulse arc welding

KW - Steel

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JO - Materials Science Forum

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ER -

Parametric Study of Pulse Arc Welding (PAW) and Laser Beam Welding (LBW) Techniques for Electrical Vehicle Battery Cells

Abstract

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Keywords

ASJC Scopus subject areas

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