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Electro-thermo-mechanical behaviours of laser joints for electric vehicle battery interconnects

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Shaikh, Usama F., Das, Abhishek, Barai, Anup and Masters, Iain (2019) Electro-thermo-mechanical behaviours of laser joints for electric vehicle battery interconnects. In: 2019 Electric Vehicles International Conference (EV), Bucharest, Romania, 3-4 Oct 2019. Published in: 2019 Electric Vehicles International Conference (EV) ISBN 9781728107912. doi:10.1109/EV.2019.8892972

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Official URL: https://doi.org/10.1109/EV.2019.8892972

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Abstract

An automotive battery pack used in electric vehicle (EV) comprises several hundred to a few thousand of individual Lithium-ion (Li-ion) cells when cylindrical cells are used to build the battery pack. These cells are connected in series and/or parallel to deliver the required power and capacity to achieve the designed vehicle driving range. This triggers the need for suitable joining methods capable of providing mechanical strength together with the required electrical and thermal performances. A range of joining techniques are currently employed to connect large numbers of cells, and of these, laser welding is estimated to be the one of most efficient methods. Typically, the cylindrical cell casing is made of electrical grade steel which is electrically connected to copper tabs representing the cylindrical cell terminal to tab interconnect within the battery pack assembly. This study focuses on identifying the effect of laser welding process parameters on the mechanical, electrical and thermal responses of the laser welded joints produced using a 150 W Quasi-CW IR laser. Mechanical strength is assessed by evaluating the lap shear strength of the joint whereas the electrical and thermal responses are captured using voltage sensors and a thermal imaging camera respectively. It was observed that mechanical strength of the joint is highly correlated with electrical resistance and corresponding temperature raise at the joint. Furthermore, the optical micrographs reveal the microstructural characteristics of the joint.

Item Type: Conference Item (Paper)
Subjects: T Technology > TL Motor vehicles. Aeronautics. Astronautics
Divisions: Faculty of Science > WMG (Formerly the Warwick Manufacturing Group)
Library of Congress Subject Headings (LCSH): Electric vehicles -- Batteries, Laser welding, Electric resistance, Lithium cells -- Cooling, Thermal analysis
Journal or Publication Title: 2019 Electric Vehicles International Conference (EV)
Publisher: IEEE
ISBN: 9781728107912
Official Date: 11 November 2019
Dates:
DateEvent
11 November 2019Published
2 October 2019Accepted
DOI: 10.1109/EV.2019.8892972
Status: Peer Reviewed
Publication Status: Published
Publisher Statement: © 2019 IEEE. Personal use of this material is permitted. Permission from IEEE must be obtained for all other uses, in any current or future media, including reprinting/republishing this material for advertising or promotional purposes, creating new collective works, for resale or redistribution to servers or lists, or reuse of any copyrighted component of this work in other works.
Access rights to Published version: Restricted or Subscription Access
RIOXX Funder/Project Grant:
Project/Grant IDRIOXX Funder NameFunder ID
UNSPECIFIEDJaguar Land Rover (Firm)http://viaf.org/viaf/305209406
UNSPECIFIEDWMG centre HVM CatapultUNSPECIFIED
Conference Paper Type: Paper
Title of Event: 2019 Electric Vehicles International Conference (EV)
Type of Event: Conference
Location of Event: Bucharest, Romania
Date(s) of Event: 3-4 Oct 2019
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