The electric vehicle (EV) battery systems are complex assemblies of dissimilar materials in which battery cells are connected using several thousand interconnect joints. Every single joint influences the functionality and efficiency of the whole battery system, making the joining process crucial. Laser welding is considered a desirable choice for EV battery manufacturing due to its non-contact nature, high energy density, precise control over the heat input, and ease of automation. However, incompatible thermos-physical properties of dissimilar materials used in battery tabs and interconnectors pose a significant challenge for achieving complete metallurgical bond. Furthermore, the formation of undesirable weld microstructures such as hard and brittle intermetallic compounds (IMCs) substantially undermines the structural, electrical, and thermal characteristics of battery joints. This paper reviews the fundamental difficulties and latest developments in dissimilar laser welding of steel-copper, steel-aluminum, aluminum-copper, and steel-nickel, some of the potential joint combinations in EV battery pack manufacturing. The weld microstructure and common metallurgical defects, as well as mechanical and electrical properties of joints are discussed. In addition, the effects of laser welding process parameters on the joint properties and the applicability of various interlayers and coatings in laser welding of battery materials are assessed. 

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A review on dissimilar laser welding of steel-copper, steel-aluminum, aluminum-copper, and steel-nickel for electric vehicle battery manufacturing

Welding of high entropy alloys: Progresses, challenges and perspectives

The electric vehicle (EV) battery systems are complex assemblies of dissimilar materials in which battery cells are connected using several thousand interconnect joints. Every single joint influences the functionality and efficiency of the whole battery system, making the joining process crucial. Laser welding is considered a desirable choice for EV battery manufacturing due to its non-contact nature, high energy density, precise control over the heat input, and ease of automation. However, incompatible thermos-physical properties of dissimilar materials used in battery tabs and interconnectors pose a significant challenge for achieving complete metallurgical bond. Furthermore, the formation of undesirable weld microstructures such as hard and brittle intermetallic compounds (IMCs) substantially undermines the structural, electrical, and thermal characteristics of battery joints. This paper reviews the fundamental difficulties and latest developments in dissimilar laser welding of steel-copper, steel-aluminum, aluminum-copper, and steel-nickel, some of the potential joint combinations in EV battery pack manufacturing. The weld microstructure and common metallurgical defects, as well as mechanical and electrical properties of joints are discussed. In addition, the effects of laser welding process parameters on the joint properties and the applicability of various interlayers and coatings in laser welding of battery materials are assessed.

Glass and metal have wide applications in various industries due to their excellent properties. To make the most use of their properties and enlarge their applications, it is important to bond the glass and metal. Many bonding methods of glass and metal in recent years are reviewed in this article. The advantages and deficiencies of different bonding methods are discussed. The main problems between glass and metal in bonding process are proposed, and some suggestions to solve these problems are introduced. Finally, the development direction of bonding methods for glass and metal in the future is discussed.

The bonding between glass and metal

AA6061 alloy sheets have been successfully spot-welded to dual-phase DP600 steel sheets with pinless friction stir spot welding method. The Box-Behnken design of experiments was implemented to arrange the tests. The individual and interaction effect of each process parameter on the lap-shear failure load of the joints was investigated. The maximum failure load of 4.4 kN was achieved at 1300 rpm rotational speed, 2000 kg axial force, and 10 s welding time. Microstructural features of the interfaces and phase evolution were studied by scanning electron microscope and X-ray diffraction, respectively. The bonding mechanisms at the joint interface are classified into two types: thick intermetallic layer (type I), and thin intermetallic layer with thick Zn–Al diffusion region (type II) in the aluminum/steel interface.

Pinless FSSW of DP600/Zn/AA6061 dissimilar joints

An YLS6000 continuous laser was used to weld DP980 to a 1.5 mm thick A6061, and Cu foil with different thickness was pre-placed at the joint prior. According to this, the effect of Cu content on the microstructure transformation and mechanical properties of the microstructure and the mechanical properties of the Fe-Al laser welded joints were discussed, and summed up in two points: On one hand, a higher Cu content was in favor of generating a weld seam with a low δ-ferrite content, and the microhardness increased from 277 HV to 346 HV. On the other hand, Cu stacked on the surface of the Fe-Al intermetallic compounds (IMCs) and suppressed the interdiffusion of Fe and Al, while also replacing Fe to generate (Fe, Cu)2Al5 and (Fe, Cu)Al3, which have excellent mechanical properties. Thus, a higher Cu content was beneficial for decreasing the microhardness and thickness of the IMCs layer and improving the shear tensile strength of the welded joints, which was ~7% higher than that of the directly welded samples.

Effect of Cu content on microstructure transformation and mechanical properties of Fe-Al dissimilar laser welded joints

In order to further optimize welding process of Nb–Ti–Mo microalloyed steel, welding thermal cycles on coarse-grained heat-affected zone (CGHAZ) of welded joints were simulated using Gleeble 1500 The microstructure and low-temperature impact fracture were investigated using a scanning electron microscope and a pendulum impact machine, respectively Moreover, the relationship between cooling time t8/5 and the microstructure of CGHAZ was discussed, and the effect of microstructure on impact toughness was also studied As cooling time increased, martensite fraction decreased from 978% (3 s) to 30% (60 s) The fraction of martensite/austenite (M/A) constituent increased from 22% (3 s) to 390% (60 s), its shape changed from granular to strip, and the maximum length increased from 24 μm (3 s) to 70 μm (60 s) As cooling time increased, the prior austenite grain size increased from 340 μm (3 s) to 490 μm (60 s), the impact absorption energy reduced from 1018 J (5 s) to 72 J (60 s), and the fracture mechanism changed from quasi-cleavage fracture to cleavage fracture The decreased toughness of CGHAZ was due to the reduction of lath martensite-content, coarsening of original austenite grain, and increase and coarsening of M/A constituent The heat input was controlled under 7 kJ cm−1 during actual welding for these steels

Effect of cooling time t8/5 on microstructure and toughness of Nb–Ti–Mo microalloyed C–Mn steel

The invention discloses a laser welding method for a steel/aluminum dissimilar material. According to the laser welding method, an Al2O3 oxidation layer on the surface of an aluminum alloy does not need to be removed, and a Ni/B powder mixture is prearranged on the surface of the aluminum alloy, wherein the mass percentage of B powder ranges from 5% to 15%; laser welding is conducted in the atmosphere of inert gas mixed with a CO2/O2 gas mixture or air, so that the metallurgical reaction in a molten pool is improved through Ni in the Ni/B powder mixture, occurrence of the Fe-Al metallurgical reaction is effectively hindered, and a Fe-Al intermetallic compound at an interface of a welding joint is inhibited from being separated; the B powder is molten and enters the welding molten pool, sothat toughness of an Al-Ni intermetallic compound generated after the Ni is added is improved; either or both of O2 or CO2 are adopted to be mixed with the inert gas, or welding is conducted directlyin a pure air environment, so that the oxygen partial pressure of the welding molten pool is increased, and an element Al and an element O entering the molten pool are combined to form Al2O3 which does not affect the toughness of the welding joint; the thickness of the Fe-Al intermetallic compound at the interface is reduced, and strengthening and toughening of the steel/aluminum dissimilar welding joint are achieved; and the high-quality laser welding joint is obtained.

Laser welding method for steel/aluminum dissimilar material

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Effect of Cu content on microstructure transformation and mechanical properties of Fe-Al dissimilar laser welded joints

Effect of cooling time t8/5 on microstructure and toughness of Nb–Ti–Mo microalloyed C–Mn steel

Laser welding method for steel/aluminum dissimilar material