The BusBar represents a crucial component in the production of power batteries. The primary method for connecting the BusBar to the electric core is laser welding. Most contemporary laser welding researchers uses a Gaussian laser, which is prone to spattering during BusBar welding process. This spattering would negatively impact the quality of the welding between the busbar and the electric core. To address this issue, this paper presents a solution to suppress the spatter phenomenon during BusBar laser welding by superimposing an additional ring laser on top of the conventional Gaussian laser. This study employs multi-physics simulation software to examine the impact of the ring laser on the keyhole dimensions at varying power levels (0 W to 1000 W) and compares the findings with experimental data. The findings indicate that the depth and width of the laser weld tend to increase with the augmentation of the ring laser power. Furthermore, the entrance diameter of the lock hole reaches its maximum at 750 W ring laser power and then declines. Due to the increased stability of the keyhole due to the larger keyhole inlet and increased melt depth and width, collapse is reduced and spatter is minimized during the BusBar laser welding process. As a result, spatter is most effectively mitigated at 750 W ring laser power. To gain further insight into spatter suppression by the ring laser, this paper investigates the flow behavior of the molten pool and spatter formation during BusBar laser welding at 750 W ring laser power. The simulation results show that using the ring laser significantly reduces the temperature gradient around keyhole and slows the flow rate of the surrounding melt. Consequently, the molten metal cannot gain enough momentum to leave the molten pool surface, effectively suppressing spatter formation and enhancing the surface finish.

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Simulation and Experimental Verification for Reducing Spatter in BusBar Laser Welding with Superimposed Ring Laser

  • Yangxin Chen,
  • Ligang Yao,
  • Yaming Liu,
  • Jiaxin Ding,
  • Minlong Huang,
  • Biaolin Luo

摘要

The BusBar represents a crucial component in the production of power batteries. The primary method for connecting the BusBar to the electric core is laser welding. Most contemporary laser welding researchers uses a Gaussian laser, which is prone to spattering during BusBar welding process. This spattering would negatively impact the quality of the welding between the busbar and the electric core. To address this issue, this paper presents a solution to suppress the spatter phenomenon during BusBar laser welding by superimposing an additional ring laser on top of the conventional Gaussian laser. This study employs multi-physics simulation software to examine the impact of the ring laser on the keyhole dimensions at varying power levels (0 W to 1000 W) and compares the findings with experimental data. The findings indicate that the depth and width of the laser weld tend to increase with the augmentation of the ring laser power. Furthermore, the entrance diameter of the lock hole reaches its maximum at 750 W ring laser power and then declines. Due to the increased stability of the keyhole due to the larger keyhole inlet and increased melt depth and width, collapse is reduced and spatter is minimized during the BusBar laser welding process. As a result, spatter is most effectively mitigated at 750 W ring laser power. To gain further insight into spatter suppression by the ring laser, this paper investigates the flow behavior of the molten pool and spatter formation during BusBar laser welding at 750 W ring laser power. The simulation results show that using the ring laser significantly reduces the temperature gradient around keyhole and slows the flow rate of the surrounding melt. Consequently, the molten metal cannot gain enough momentum to leave the molten pool surface, effectively suppressing spatter formation and enhancing the surface finish.