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Applying optical coherence tomography for weld depth monitoring in remote laser welding of automotive battery tab connectors
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Sokolov, Mikhail, Franciosa, Pasquale, Sun, Tianzhu and Ceglarek, Dariusz (2020) Applying optical coherence tomography for weld depth monitoring in remote laser welding of automotive battery tab connectors. Journal of Laser Applications, 33 (1). 012028. doi:10.2351/7.0000336 ISSN 1042-346X.
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WRAP-Applying-optical-coherence-tomography-weld-laser-battery-2020.pdf - Accepted Version - Requires a PDF viewer. Download (2090Kb) | Preview |
Official URL: https://doi.org/10.2351/7.0000336
Abstract
This paper addresses in-process monitoring of weld penetration depth (WPD) during remote laser welding of battery tab connectors using optical coherence tomography (OCT). The research aims at studying the impact of welding process parameters on the accuracy of WPD measurements. In general, the highest measurement accuracy is achievable by positioning the OCT measuring beam toward the bottom of the keyhole. However, finding and maintaining the alignment between the OCT measuring beam and the bottom of the keyhole is a challenging task because of the dynamic changes in the size and shape of the keyhole itself. The paper addresses the above challenge by (1) developing welding process parameters for the Al-Cu thin foil lap joint (Al 1050 foil 450 μm and Ni-plated Cu foil 300 μm) using a novel adjustable ring mode (ARM) laser and (2) integrating OCT technology with two beams: one targeting the bottom of the keyhole and another as a reference to the part surface (TwinTec technology). The methodology is underpinned by the “Keyhole Mapping” approach, which helps one to identify the optimal placement of the OCT measuring beam with considerations to both measurement accuracy and stability of the keyhole. Findings indicated that welding with the ARM laser results in a more stable process, reduces fluctuations of the keyhole opening, and, therefore, helps one to improve the measurement accuracy by a factor of 50% (from the average error of 0.22 mm to 0.11 mm). Results further identified that the feasible operating window of the OCT measuring beam, corresponding to the highest measurement accuracy, is below 20 μm in length.
Item Type: | Journal Article | ||||||||||||
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Subjects: | T Technology > TA Engineering (General). Civil engineering (General) T Technology > TJ Mechanical engineering and machinery T Technology > TK Electrical engineering. Electronics Nuclear engineering T Technology > TS Manufactures |
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Divisions: | Faculty of Science, Engineering and Medicine > Engineering > WMG (Formerly the Warwick Manufacturing Group) | ||||||||||||
Library of Congress Subject Headings (LCSH): | Laser welding, Copper -- Welding, Aluminum, Optical coherence tomography, Electric batteries | ||||||||||||
Journal or Publication Title: | Journal of Laser Applications | ||||||||||||
Publisher: | Laser Institute of America | ||||||||||||
ISSN: | 1042-346X | ||||||||||||
Official Date: | 29 December 2020 | ||||||||||||
Dates: |
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Volume: | 33 | ||||||||||||
Number: | 1 | ||||||||||||
Article Number: | 012028 | ||||||||||||
DOI: | 10.2351/7.0000336 | ||||||||||||
Status: | Peer Reviewed | ||||||||||||
Publication Status: | Published | ||||||||||||
Access rights to Published version: | Restricted or Subscription Access | ||||||||||||
Description: | Special topic on Proceedings of the International Congress of Applications of Lasers & Electro-Optics 2020 |
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Date of first compliant deposit: | 8 January 2021 | ||||||||||||
Date of first compliant Open Access: | 11 January 2021 | ||||||||||||
RIOXX Funder/Project Grant: |
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