Description

Joining materials with dissimilar metallurgical properties are still a challenge among others in modern battery cell production and e-mobility. Of particular importance for these application fields is generating electrical connections with high conductivity and high mechanical stability in a productive manner. On the same time excellent control of the welding depth must be ensured in order to protect the underlying battery structure. In the present paper we present advances in strategies for joining dissimilar materials like copper and aluminum to realize battery connections by implementing distinct laser welding strategies with a fast oscillating single mode laser beam. The high beam quality enables a stable in coupling into high reflective copper connectors with low spatter events. To achieve joints with high electric conductivity a beam oscillation pattern is executed in order to create adequate cross-sections to enable high current flow. This is essential for fast battery charging and extended lifetime of the batteries. The mechanical stability is achieved in a micro structured manner in such a way wherein the created intermetallic phase zone between copper and aluminum is minimized by implementing very accurate and very small metal mixture through compression of isotherms and melt flow guidance. TRUMPF’s new generation of the product line TruFiber together with the optimally matched scanner optics (PFO series) have been implemented to demonstrate the above strategy.

Contributing Authors

  • Evangelos Papastathopoulos
    TRUMPF Laser- und Systemtechnik GmbH
  • Elke Kaiser
    TRUMPF Laser GmbH
  • Christian Jauch
    TRUMPF Laser GmbH
  • Guenther Ambrosy
    TRUMPF Laser- und Systemtechnik GmbH
  • Alexander Killi
    TRUMPF Laser GmbH
Evangelos Papastathopoulos
TRUMPF Laser- und Systemtechnik GmbH
Track: Laser Materials Macroprocessing
Session: Welding I
Day of Week: Monday
Date/Time:
Location:

Keywords

  • Battery, Connector, E-Mobility
  • Single Mode, Oscillation, Wobble, Laser, Fiber, Scanner
  • Welding, Copper, Aluminum, Dissimilar