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<p>The effect of laser source on the welding characteristics of Al alloys is studied for Li-ion battery&#xa0;applications. AA3003 sheets of 0.8&#xa0;mm thickness used for Li-ion battery containers are welded using Pulsed wave (PW) laser and continuous wave (CW) laser, both having the same laser energy of 120&#xa0;J and compared for their microstructure and mechanical properties. Microstructural analysis indicated that the PW weld has more surface defects and lower depth of fusion. The weld joint prepared by CW laser exhibit complete depth of fusion, higher strength and ductility than the PW laser due to higher heat input and more fusion time. PW laser weld samples exhibit higher hardness of the weld zone due to the higher cooling rates, which lead to quench cracks, lower strength and brittle failure. The cooling rate in PW weld has been calculated to be double that of CW weld which reduces the grain size by an order of magnitude in the PW weld. CW laser weld meets both the internal and external pressures exerted in Li-ion batteries and is found beneficial.</p>

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Effect of Laser Source on the Weld Quality of Al Alloys for Li-ion Battery Applications

  • 期刊论文

  • 发表日期：

    2026年5月2日

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  • I. Umalalitha,
  • M. Srinivas,
  • D. Lingaraju

摘要

The effect of laser source on the welding characteristics of Al alloys is studied for Li-ion battery applications. AA3003 sheets of 0.8 mm thickness used for Li-ion battery containers are welded using Pulsed wave (PW) laser and continuous wave (CW) laser, both having the same laser energy of 120 J and compared for their microstructure and mechanical properties. Microstructural analysis indicated that the PW weld has more surface defects and lower depth of fusion. The weld joint prepared by CW laser exhibit complete depth of fusion, higher strength and ductility than the PW laser due to higher heat input and more fusion time. PW laser weld samples exhibit higher hardness of the weld zone due to the higher cooling rates, which lead to quench cracks, lower strength and brittle failure. The cooling rate in PW weld has been calculated to be double that of CW weld which reduces the grain size by an order of magnitude in the PW weld. CW laser weld meets both the internal and external pressures exerted in Li-ion batteries and is found beneficial.