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<p>This study explored the application of laser welding for joining aluminum and Hilumin® for a cell-to-tab joints in Li-ion battery packs examining influence of laser-related parameters such as welding speed, laser power, and oscillation amplitude on the properties of welds and optimized the parameters by using Taguchi method. Initially, aluminum and Hilumin® sheet materials were joined with laser welding. Electrical resistances of the welded samples were measured. Then, lap shear strengths were determined using the tensile device. As a result of the optimizations, it was determined which laser welding parameters would result in the minimal electrical resistance and maximal joint strength. In this study, the preferred minimum electrical resistance and maximum joint strength values for battery interconnection joints, with varying laser power, welding speed, and oscillation amplitude parameters, were achieved with a combination of 890 W power, 1&#xa0;mm oscillation amplitude, and 8.5&#xa0;m/min speed. If optimum parameters are used in establishing the connection, the maximum weld seam strength achieved was 32.36&#xa0;MPa, and the minimum electrical contact resistance was 0.4186 mΩ. Findings show that welding speed strongly influenced the microstructure and mechanical and electrical properties of the welds, with higher speeds enhancing lap shear strength and reducing electrical contact resistance by favoring ductile Fe-rich intermetallic formation, while lower speeds led to brittle Al-rich intermetallics. Increasing the welding speed also increased the strength of connection.</p>

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A comprehensive study on the optimization of laser welding process parameters for electric vehicle battery interconnections

  • 期刊论文

  • 出版模式：

    开放获取

  • 发表日期：

    2026年5月21日

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  • Aygen Ahsen Yıldırım,
  • Erol Feyzullahoğlu,
  • Rıdvan Yamanoğlu

摘要

This study explored the application of laser welding for joining aluminum and Hilumin® for a cell-to-tab joints in Li-ion battery packs examining influence of laser-related parameters such as welding speed, laser power, and oscillation amplitude on the properties of welds and optimized the parameters by using Taguchi method. Initially, aluminum and Hilumin® sheet materials were joined with laser welding. Electrical resistances of the welded samples were measured. Then, lap shear strengths were determined using the tensile device. As a result of the optimizations, it was determined which laser welding parameters would result in the minimal electrical resistance and maximal joint strength. In this study, the preferred minimum electrical resistance and maximum joint strength values for battery interconnection joints, with varying laser power, welding speed, and oscillation amplitude parameters, were achieved with a combination of 890 W power, 1 mm oscillation amplitude, and 8.5 m/min speed. If optimum parameters are used in establishing the connection, the maximum weld seam strength achieved was 32.36 MPa, and the minimum electrical contact resistance was 0.4186 mΩ. Findings show that welding speed strongly influenced the microstructure and mechanical and electrical properties of the welds, with higher speeds enhancing lap shear strength and reducing electrical contact resistance by favoring ductile Fe-rich intermetallic formation, while lower speeds led to brittle Al-rich intermetallics. Increasing the welding speed also increased the strength of connection.