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A multi-physics CFD study on the part-to-part gap during remote laser welding of copper-to-steel battery tab connectors with beam wobbling
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Chianese, Giovanni, Jabar, Sharhid, Franciosa, Pasquale, Ceglarek, Dariusz and Patalano, Stanislao (2022) A multi-physics CFD study on the part-to-part gap during remote laser welding of copper-to-steel battery tab connectors with beam wobbling. In: 12th CIRP Conference on Photonic Technologies [LANE 2022], 4-8 Sep 2022, Fürth, Germany. Published in: Procedia CIRP, 111 pp. 484-489. doi:10.1016/j.procir.2022.08.075 ISSN 2212-8271.
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WRAP-multi-physics-CFD-study-part-to-part-gap-during-remote-laser-welding-copper-to-steel battery-tab-connectors-with-beam-wobbling-2022.pdf - Accepted Version - Requires a PDF viewer. Available under License Creative Commons Attribution Non-commercial No Derivatives 4.0. Download (717Kb) | Preview |
Official URL: https://doi.org/10.1016/j.procir.2022.08.075
Abstract
Remote Laser Welding (RLW) of dissimilar metallic thin foils (below 500 µm) has fundamental importance in battery pack manufacturing where high repeatability is a strict requirement. Since the welding process is very sensitive to part-to-part gaps, it is critical to understand the physical phenomena during melting, formation of the keyhole and solidification. This study has been designed to investigate the underlying physics of the welding process and understand the influence of the laser beam wobbling and part-to-part gap on temperature fields and metal mixing. A CFD multi-physics model has been implemented and then calibrated with experimental data. Two scenarios with part-to-part gap (0 and 100 µm) have been considered during lap welding of 300 µm copper to 300 µm nickel-plated steel, with circular beam wobbling. The study has highlighted that the part-to-part gap leads to uncontrolled metal mixing. Potential strategies for weld optimization are discussed throughout the paper.
| Item Type: | Conference Item (Paper) | |||||||||
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| Subjects: | H Social Sciences > HD Industries. Land use. Labor T Technology > TA Engineering (General). Civil engineering (General) 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): | Battery industry , Storage batteries , Laser welding, Photonics | |||||||||
| Journal or Publication Title: | Procedia CIRP | |||||||||
| Publisher: | Elsevier | |||||||||
| ISSN: | 2212-8271 | |||||||||
| Official Date: | 6 September 2022 | |||||||||
| Dates: |
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| Volume: | 111 | |||||||||
| Page Range: | pp. 484-489 | |||||||||
| DOI: | 10.1016/j.procir.2022.08.075 | |||||||||
| Status: | Peer Reviewed | |||||||||
| Publication Status: | Published | |||||||||
| Access rights to Published version: | Open Access (Creative Commons) | |||||||||
| Date of first compliant deposit: | 11 July 2022 | |||||||||
| Date of first compliant Open Access: | 11 July 2022 | |||||||||
| RIOXX Funder/Project Grant: |
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| Conference Paper Type: | Paper | |||||||||
| Title of Event: | 12th CIRP Conference on Photonic Technologies [LANE 2022] | |||||||||
| Type of Event: | Conference | |||||||||
| Location of Event: | 4-8 Sep 2022 | |||||||||
| Date(s) of Event: | Fürth, Germany | |||||||||
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