Experimental Analysis Summary of Laser Welding Process for Power Battery Tabs
Release time: 2017-12-25
Experimental Analysis Summary of Laser Welding Process for Power Battery Tabs
Published on: 2017-12-25
Experimental Objective:
To weld four 0.2mm tabs (aluminum or nickel-plated copper tabs) stacked together onto an aluminum or copper terminal, achieving smooth weld seams.
Experimental Setup:
- Laser: YLS-4000 (100μm fiber)
- Mode: CW (Continuous Wave)
- Laser Head (Nozzle): D50 (output power up to 50kW)
- Focal Length: FC=200, FF=250mm
- Motion System: Four-axis motion platform
Materials Used:
- Material Types: Aluminum sheets, nickel-plated copper sheets, aluminum terminals
- Form: Sheets
- Dimensions: 0.2mm tabs, 1mm terminals
Experimental Results:
1. Welding 4 Nickel-Plated Copper Tabs to Copper Terminal:
- Power: 2400W
- Thickness: 1mm (4 layers)
- Speed: 100 mm/s
2. Welding 4 Aluminum Tabs to Aluminum Terminal:
- Power: 1600W
- Thickness: 1mm (4 layers)
- Speed: 100 mm/s
Case Summary:
1. Use of Fixtures: Welding results improved significantly with the use of fixtures.
2. Welding Method: Each weld seam was welded separately.
3. Key Factor: The tightness of the tabs during welding had the greatest impact on weld quality. Tightly pressed tabs resulted in better welds compared to loosely pressed ones.
4. Material Gap: For laser welding, maintaining an appropriate gap between materials is crucial.
- Too Small: Gases produced during welding cannot escape, leading to porosity.
- Too Large: Risk of burn-through, affecting weld quality.
This experiment highlights the importance of proper material preparation and fixture design in achieving high-quality laser welds for power battery tabs.
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