Optimization of Laser-Welded Cu-Al Joints for Electric Vehicle Battery Cases

Abstract With the development of electric vehicles, research on materials linked to the handling of batteries has gained significant attention. Among these, copper-aluminum joints have emerged as a key solution for battery terminals, due to the need of high electrical conductivity, suitable mechanical properties and good corrosion resistance. In this paper, the aim is to characterize above-mentioned laser-welded joints, and subsequently to study the influences of the main welding parameters, such as ring, core power and speed, on the selected response factors through experimental design. Obtained results demonstrate that the appropriate adjustment of setting parameters reduces electrical resistance, enhances mechanical strength and minimizes the formation of brittle intermetallic compounds, thus allowing for an improvement in both the quality and performance of the joint.