A Novel AMB Laser Welding of Copper Eyelets onto Aluminum Busbars

The necessity of bonding copper and aluminum in certain Electric vehicle battery pack applications arises from the advantageous properties they each offer: copper excels in conductivity and response, while aluminum contributes to weight reduction. In many instances, the bonding of aluminum and copper can be accomplished through methods such as adhesive bonding, mechanical fastening, fusion welding, and solid-phase welding. Laser welding, renowned for its capacity to join aluminum to a variety of metals, is now receiving serious consideration. This study focuses on achieving a robust connection between two dissimilar metals: pre-strained aluminum and commercially pure copper. Commercial pure aluminum is intentionally strained to narrow the strength gap between the two materials, and the impact of pre-strain on Laser welding is examined. To facilitate a strong joint, nickel plating is added over the pure copper eyelet. This paper presents comparative analysis of both Bolting and AMB laser welding technology in battery pack. Proposed AMB laser welding is cost effective with more reliability and benefits as compared to manual bolting type.