This study aims to reduce heat generation and enhance the strength of busbar welding in prismatic lithium-ion battery modules, crucial for electric vehicles. Effective heat management during welding is essential to maintain battery connections' integrity and prevent thermal runaway, a potentially catastrophic failure. High temperatures during welding can accelerate battery life degradation, damage sealing rubber and O-rings, and increase internal battery pressure. We conducted a comparative analysis between continuous wave (CW) laser welding and the pulsing welding method using Aluminum 1100 series with a thickness of 2mm on the top battery terminal. Temperature measurements were taken at the bottom of the terminal during tests to monitor heat distribution. CT scans assessed porosity and detected micro-cracks within the welding zone, critical for determining weld durability. Additionally, tensile tests evaluated the mechanical properties of the welds.


The results showed that the pulsing laser welding method produced significantly lower temperatures than CW welding, reducing the risk of thermal damage. The pulsing method also resulted in less porosity, indicating a more uniform weld structure. These findings suggest that pulsing laser welding offers superior performance in thermal management and weld integrity. The advancements identified in this study are expected to contribute to the widespread adoption of electric vehicles by ensuring that their battery packs are robust and resilient under various operational conditions.