Energy storage box welding

What is ultrasonic welding?

Ultrasonic welding is commonly used for the joining of the internal electrode battery materials, which are usually constructed of thin foils of aluminum and copper. The remaining joining requirements – including the connections inside the can, and external terminal tab connections – are well suited to resistance, microTIG, and laser welding.

What materials can be welded with laser welding?

For tab and buss bar joining, laser welding offers a high degree of flexibility, welding both thin and thick tab materials, and materials such as copper, aluminum, steel and nickel as well as dissimilar material combinations. Two example welds are shown in Figure 4.

What is resistance welding?

Resistance welding has been an established joining technology for more than 40 years and has been used in the battery industry for almost as long. Since then, a steady stream of advances in resistance welding systems has given users significantly improved capabilities to control various aspects of the process.

What is tungsten inert gas welding?

Similar to resistance welding, tungsten inert gas welding (TIG), also known as gas tungsten arc welding, has been used in manufacturing for many decades and has traditionally been used for the more challenging welding applications for nonferrous materials.

What are the important aspects of Tab welding?

From a welding perspective, the important aspects of tab welding are the thickness and material of both the tab and the terminal. Resistance welding is extremely well suited to welding nickel tab material up to 0.015-inch thickness, and nickel or steel clad copper tab material to around 0.012-inch thickness to a wide variety of terminal materials.

Is micro-Tig a good welding material?

Micro-TIG offers excellent welding of copper, and so presents a good solution for buss bar welding that would require a brazing material for resistance welding or a large power laser welder. Both butt, fillet and lap welds are possible up to and beyond thickness of 0.02 in thick copper are routinely welded.