Power batteries have many laser welding parts. The materials are mainly aluminum alloys. A small number of parts are made of copper, nickel and other materials, and a very few use stainless steel as the battery casing. Among these materials, the laser welding process of nickel and stainless steel is relatively simple. It is also more mature, but there are still many difficulties in laser welding of aluminum alloy and copper. In addition to the influence of material properties, the state of the welded joint will also have a greater impact on the welding effect.

1. Type and status of materials to be welded

Types of materials to be welded:

When aluminum alloy and copper are used as materials to be welded, the main reasons for the poor results of conventional laser welding are:

1. Both are highly reflective materials for fiber lasers, and their absorption rate for fiber lasers is not high, resulting in poor stability of the welding process;

2. The thermal conductivity of the two is good, but the welding seam is difficult to form and is prone to pores.

At the same time, there are certain differences between the two materials. Relatively speaking, the absorption rate of aluminum alloy for fiber laser is higher than that of red copper, and the thermal conductivity of red copper is better than that of aluminum alloy. Therefore, the solutions to the difficulties of laser welding between the two are: In the same places, there are also certain differences:

Aluminum alloy solutions:

1. Use a relatively small focused spot (0.1mm-0.3mm) for welding;

2. The welding speed cannot be too low and should be controlled above 60mm/s;

3. Use fiber-semiconductor laser hybrid welding;

4. Use swing welding.

Copper solution:

1. Use a smaller focused spot (0.02mm-0.2mm) for welding;

2. The welding speed should be fast, it is recommended to be above 100mm/s;

3. Use swing welding.

Material status to be welded

The state of the material to be welded described in this article refers to the surface cleanliness and pretreatment degree of the material. These conditions will lead to poor weld quality. Specific results and solutions:

1. There are impurities on the surface of the material.

Difficulty performance:

There are pores in the weld, the sealing is not enough, and the strength is not enough;

If the weld seam has explosive spots, the product will be scrapped.

Solution: Impurities such as oil stains and water stains need to be removed from the materials to be welded before welding.

2. The oxide on the surface of the aluminum alloy is not cleaned

Difficulty performance:

The weld seam has more pores, insufficient sealing, and insufficient strength;

The molding is unstable and the yield rate is reduced.

Solution: Remove the oxide film from the materials to be welded before welding, and then weld as soon as possible.

3. The material to be welded is rough in processing

Difficulty performance:

Uneven molding and poor appearance;

Welding leaks are prone to occur and there is no sealing.

Solution: The material must be machined and must be flat and without deformation.

2. Types and requirements of components to which welds belong

There are currently three mainstream automotive power batteries, namely prismatic batteries, cylindrical batteries and soft pack batteries. The prismatic battery is the most commonly used, and it is also the battery type with the most laser welding parts. The market share of the other two types of batteries and the demand for laser welding are relatively much less.

The main problems of welds are insufficient strength, insufficient sealing and poor shaping, which lead to the occurrence of these problems. Their commonality is that the selection of the welding process is incorrect. In addition, there are welding difficulties caused by the structure of the part to be welded and its weld requirements. , specific situations and solutions:

1. Soft pack battery components-lugs/busbars

  Difficulties in welding: The material is thin, and multiple pieces are easily welded together, resulting in insufficient strength and poor conductivity.

Solution: Control the flatness of incoming materials; design clamps with excellent performance and control the clamping gap.

Difficulties in welding: Insufficient width of weld connection leads to insufficient strength.

Solution: Choose a small core fiber laser and use swing welding.