Investigating performance and reliability of resistance spot welds on additively manufactured battery tabs using microscopic resolution ultrasonic imaging

Abstract This publication focuses on a comprehensive study into the performance of resistance spot welding on additively manufactured battery tabs for electric applications. Due to the rapid prominence of electric vehicles, there is an urgent need to understand the reliability and overall efficiency of battery systems. The battery tabs in electric vehicles are critical components within the battery system that affect the overall performance and reliability. Furthermore, with the emergence of additive manufacturing, innovative design concepts of battery tabs can be fabricated cost-effectively while also reducing waste. This study explores the feasibility of using additively manufactured aluminum and stainless steel battery tabs joined by resistance spot welding processes and utilizing an ultrasound-based inspection method to assess the weld quality. A microscopic resolution ultrasonic imaging system is used to nondestructively examine and characterize welded nuggets at the interface. The findings of this study focus on further development of sophisticated electric vehicle battery tabs through materials engineering, manufacturing processing, welding processes, and nondestructive evaluation. This research is important for addressing electric vehicle battery technology and ensures the growth and sustainability of electric transportation.