Spatter Behavior in Al-Cu Adjustable Ring Mode Laser Spot Welding

Adjustable ring mode laser has been increasingly adpoted for welding of aluminum leads and copper busbar in the manufacturing of lithium-ion batteries. Spatter generated during welding can penetrate into the cell and potentially cause performance degradation, internal short circuits, or even thermal runaway. To prevent such defects, it is essential to understand the motion characteristics of spatters at the moment of ejection. In this study, high-speed camera was employed to capture the spatter behavior, and the acquired frames were processed through image processing. Subsequently, spatters were tracked using a Hungarian algorithm based assignment method, enabling quantitative extraction of spatter size, speed, and ejection angle. The results provide dynamic behavior of spatter during adjustible ring mode laser spot welding of aluminum and copper.