Investigating laser and ultrasonic welding of pouch cell multi-foil current collectors for electric vehicle battery fabrication

Abstract The escalating necessity for more efficient and defect-free joining of ‘ultra-thin foil collectors-to-tabs’ in electric vehicle (EV) Li-ion pouch cells motivates this study. The prevalent ultrasonic welding (USW) method for these joint types, faces limitations such as design constraints and access requirements, laser welding (LW) emerges as a promising alternative offering flexibility, one-side access and faster speeds with efficient heat input. This study aims to investigate the feasibility of LW as a viable alternative to USW for joining current collectors-to-tab joints. It compares the mechanical, metallurgical, electrical and thermal analysis of the joints to evaluate both welding techniques for joint defects. The comparison of solid-state material mixing during USW and the intermixing of aluminium (Al) and copper (Cu) during fusion LW using EDX analysis presents interesting observations in the study. The USW generates a thin transition layer with intermetallic compounds (IMCs) attributed to the diffusion of Cu into the Al matrix during joining, which is comparatively lower as in the case of LW with higher material mixing with brittle IMCs like Al 2 Cu and Al 4 Cu 9 . However, the joint strength of LW is comparatively lower than the USW joint attributed to the reduced fusion zone area. Furthermore, from the electrical contact resistance and the joint temperature analysis, it was found that the resistance and temperature vary by as much as 13% and 6%, respectively, for the 50 A and 75 A passing currents when the USW is replaced with the LW process.