The DOI matches its Crossref record; 3 of the 3 references it cites were found in a registry or an index.
A review on dissimilar laser welding of steel-copper, steel-aluminum, aluminum-copper, and steel-nickel for electric vehicle battery manufacturing
Open accessAbstract
3 The electric vehicle (EV) battery systems are complex assemblies of dissimilar materials in which battery 4 cells are connected using several thousand interconnect joints. Every single joint influences the 5 functionality and efficiency of the whole battery system, making the joining process crucial. Laser welding 6 is considered a desirable choice for EV battery manufacturing due to its non-contact nature, high energy 7 density, precise control over the heat input, and ease of automation. However, incompatible thermos8 physical properties of dissimilar materials used in battery tabs and interconnectors pose a significant 9 challenge for achieving complete metallurgical bonds. Furthermore, the formation of undesirable weld 10 microstructures such as hard and brittle intermetallic compounds (IMCs) substantially undermines the 11 structural, electrical, and thermal characteristics of joints. This paper reviews the fundamental difficulties 12 and latest developments in dissimilar laser welding of steel-copper, steel-aluminum, aluminum-copper, and 13 steel-nickel alloys, the potential joint combinations in EV battery pack manufacturing. The microstructure 14 and common metallurgical defects, as well as mechanical and electrical properties of joints are discussed. 15 In addition, the effects of laser welding process parameters and various interlayers and coatings on the joint 16 properties of EV battery welds are assessed. 17 18
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Citations
Cites
Electric Vehicles Batteries: Requirements and Challenges
Deng, J., Bae, C., Denlinger, A., & Miller, T. (2020) · Joule · doi:10.1016/j.joule.2020.01.013 · Cited by 761
Dimatteo, V., Ascari, A., & Fortunato, A. (2019) · Journal of Manufacturing Processes · doi:10.1016/j.jmapro.2019.06.002 · Cited by 149
Saariluoma, H., Piiroinen, A., Unt, A., Hakanen, J., Rautava, T., & Salminen, A. (2020) · Batteries · doi:10.3390/batteries6030047 · Cited by 48
Cited by
Mechanism of ultrasonic effects on thermal-stress field in Cu/Al-FSW process
Zhao, W., Zhu, Y., Liu, Z., Fu, A., & He, H. (2024) · International Journal of Mechanical Sciences · doi:10.1016/j.ijmecsci.2024.109101 · Cited by 35
Investigation of corrosion and electrical resistance in laser welded Al-Cu joints for EV batteries
Sinhmar, S., Mandal, S., Yadav, V. K., & Mondal, K. (2024) · Journal of Energy Storage · doi:10.1016/j.est.2024.114436 · Cited by 17
Li, S., Shu, L., Jiang, P., Jiang, S., Wu, W., Gao, Y., & Wang, Y. (2025) · Optics & Laser Technology · doi:10.1016/j.optlastec.2024.111972 · Cited by 15
Effect of Ultrasound on Microstructure and Properties of Aluminum–Copper Friction Stir Lap Welding
Zhao, W., Zhu, Y., Liu, Z., Yi, X., Wang, J., Fu, A., Wang, F., & He, H. (2024) · Metals · doi:10.3390/met14101162 · Cited by 3
Metadata
- Authors
- Sadeghian, A., & Iqbal, N.
- Venue
- Optics & Laser Technology
- Publisher
- Elsevier BV
- Published
- 2022-02
- Volume
- 146
- Pages
- 107595
- ISSN
- 0030-3992 (ISSN-L)
- OpenAlex
- W3211048786
- Cited by
- 286
- References
- 3
- FWCI
- 18.80
- Type
- journal article
- Language
- en
- Open access
- green
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