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 journalArticlepeer-review

    4 Citations (Scopus)


    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 languageEnglish
    Pages (from-to)611-617
    Number of pages7
    JournalMaterials Science Forum
    Early online date5 Jan 2021
    Publication statusE-pub ahead of print - 5 Jan 2021

    Bibliographical note

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    • 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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