Which welding methods are used in the production of battery applications?

The compared techniques are resistance spot welding, laser beam welding and ultrasonic welding. The performance was evaluated in terms of numerous factors such as production cost, degree of automation and weld quality. All three methods are tried and proven to function in the production of battery applications.

What types of welding do EV batteries need?

“In these situations, cooperative development and reliable relationships are of high value.” While there many kinds of welding, in EV battery applications the most common are resistance welding and laser welding, along with ultrasonic welding and wire bonding, and benefit from standardisation for mass production.

Why is welding important for EV battery systems?

Welding is a vitally important family of joining techniques for EV battery systems. A large battery might need thousands of individual connections, joining the positive and negative terminals of cells together in combinations of parallel and series blocks to form modules and packs of the required voltage and capacity.

Is UWB suitable for welding a cylindrical battery cell?

UWB is also suitable for creating electrical connections between cylindrical battery cells. Although proper fixation of the cell is paramount for the welding, as any significant lateral movement will reduce the vibration amplitude and consequently diminish the power of the welding process.

Why is parameter control important in battery cell welding?

Parameter control also allows LBW to adapt to the thickness of the material tabs and can create thin or thick weld nuggets. In battery cell welding it is important to create thin welds due to the relatively thin battery cases and the risk of the weld penetrating the case and thus damaging the core.

Why do battery cells need to be welded?

Battery cells are most often put into modules or packs when produced for electrically driven vehicles. The variable of greatest influence when welding battery packs is the contact resistance between the cell and the connection tab. It is crucial to minimize this variable as much as possible to prevent energy loss in the form of heat generation.