In-depth evaluation of laser-welded similar and dissimilar material tab-to-busbar electrical interconnects for electric vehicle battery pack

A recent increase in the use of electric vehicles demands an efficient and faster joining process for making electrical interconnects within battery pack. The choice tab busbar materials to produce those is mainly based on weldability, weight, electrical/ thermal conductivity cost. To meet high demand low cycle time, laser welding emerging as main technology due its ability weld a variety at speed. This paper investigates overlap producing similar dissimilar material tab-to-busbar Li-ion assembly. In this research, 0.3 mm Al, Cu, Cu[Ni] Ni tabs were welded with 1.5 Al Cu busbars using 150 W pulsed fibre system integrated wobble head. weldability joint suitability analyses conducted by evaluating strength, intermetallic compound (IMC) formation, resistance temperature rise aim developing better safer system. It was observed that maximum strength 930 N obtained from joints which approximately 109%, 44% 66% more than respectively. case connections, (1320N) tab, 152%, 71% 76% Cu[Ni], (about 560 N) slightly 520 formation CuAl2 IMCs interface joints. Weld microstructure studies provided insightful information under-weld, good-weld over-weld characterisation respect IMC correlated strength. addition, are equally important vehicle applications. change contact measured simultaneously 180 s different amplitudes current (i.e., 100 A, 200 A) passed through