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Laser wobble welding of fluid-based cooling channel joining for battery thermal management
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Kumar, Nikhil, Das, Abhishek, Dale, Tom and Masters, Iain (2021) Laser wobble welding of fluid-based cooling channel joining for battery thermal management. Journal of Manufacturing Processes, 67 . pp. 151-169. doi:10.1016/j.jmapro.2021.04.064 ISSN 1526-6125.
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WRAP-Laser-wobble-welding-fluid-based-cooling-channel-joining-2021.pdf - Accepted Version - Requires a PDF viewer. Available under License Creative Commons Attribution Non-commercial No Derivatives 4.0. Download (3008Kb) | Preview |
Official URL: https://doi.org/10.1016/j.jmapro.2021.04.064
Abstract
Aluminium alloys are increasingly used to fabricate cooling channels for the thermal management of Li-ion batteries. Cooling channel fabrication involves a number of manufacturing operations including material extrusion, forming and joining/welding. In general, welding of aluminium alloys is challenging as they are both highly reflective and thermally conductive. To address the joining challenges, this paper is focused on developing an optimised joining process to connect a thin, flanged cooling channel to the thick module manifold of the battery thermal management system to create a watertight joint with high mechanical strength. As continuous seam welding was required, laser welding was the preferred as it is a non-contact process combining high speed and precision. For this application, 0.4 mm Al cooling channel was welded with 1.5 mm Al endplate/module manifold using a wobble head integrated with 1 kW CW fibre laser system. The effect of process parameters including line energy, incident angle, laser power, welding speed and beam offset were investigated to optimise both the weld geometry and strength. Microstructure, micro-hardness and grain formation analyses were carried out to understand the metallurgical behaviour of the weld. Beam offset had the most significant effect on the responses such as weld strength, throat thickness and modified throat thickness, and laser power had a significant influence on two key geometric features of the fusion zone, i.e. penetration depth and weld width. Weld strength was optimised using a developed surrogate model and a maximum load of 646.89 N was achieved using 0.2 mm beam offset, 331.82 W laser power and 659.10 mm/min welding speed. Using this optimum combination, a leak-proof cooling channel and module manifold joint were produced for battery thermal management.
Item Type: | Journal Article | ||||||||
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Subjects: | 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): | Lithium ion batteries , Lithium ion batteries -- Cooling, Battery management systems, Laser welding , Lithium ion batteries -- Thermal properties | ||||||||
Journal or Publication Title: | Journal of Manufacturing Processes | ||||||||
Publisher: | Elsevier | ||||||||
ISSN: | 1526-6125 | ||||||||
Official Date: | July 2021 | ||||||||
Dates: |
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Volume: | 67 | ||||||||
Page Range: | pp. 151-169 | ||||||||
DOI: | 10.1016/j.jmapro.2021.04.064 | ||||||||
Status: | Peer Reviewed | ||||||||
Publication Status: | Published | ||||||||
Access rights to Published version: | Restricted or Subscription Access | ||||||||
Date of first compliant deposit: | 25 May 2021 | ||||||||
Date of first compliant Open Access: | 3 May 2022 | ||||||||
RIOXX Funder/Project Grant: |
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