Electric resistance welding

About: Electric resistance welding is a research topic. Over the lifetime, 16761 publications have been published within this topic receiving 154851 citations.

Automotive battery pack manufacturing – a review of battery to tab joining

Abstract: Automotive battery packs used for electromobility applications consist of a large number of individual battery cells that are interconnected. Interconnection of the battery cells creates an electrical and mechanical connection, which can be realised by means of different joining technologies. The adaption of different joining technologies greatly influences the central characteristics of the battery pack in terms of battery performance, capacity and lifetime. Selection of a suitable joining technology, therefore, involves several considerations regarding electrical and mechanical properties and an assessment of production and operational conditions. Particularly, during the operation of an electric vehicle, challenges and mutual dependencies of the electrical and mechanical system emerge. The present work provides an overview of interdisciplinary challenges occurring at joints which are exposed to electrical current with a strong focus on interconnecting batteries for electric cars. It summarizes common quality criteria for the joining technologies and recombines those with criteria deduced from an electrical engineering point of view. Scientific literature concerning different joining technologies in the field of battery manufacturing is discussed based on those criteria. The most common joining techniques are ultrasonic welding, wire bonding, force fitting, soldering, laser beam welding, and resistance welding. Besides those, friction stir welding, tungsten inert gas welding, joining by forming and adhesive bonding are presented.

Solid-state welding of aluminum to copper—case studies

Abstract: This paper describes procedures for the joining of aluminum with copper via solid-state welding. Welding of dissimilar materials in order to reach a high strength and durable joints is a reasonable and outstanding challenge for industrial and especially for automotive applications. Nowadays, wiring and electrical systems, as for example batteries, turn out to be main drivers for new developments in the field of dissimilar joining technologies. Joining of aluminum to copper through a melting process leads to brittle intermetallic compounds, which cause failure of the joint already during cool down. Solid-state welding technologies allow the welding below melting temperature, so that phenomena at the interface, which lead to the formation of intermetallics under different conditions, are of interest to the resulting joint properties. Not only mechanical properties, but electrical resistivity and heat conduction are strongly dependent on those effects. Diffusion welding is performed as a model welding procedure, while friction stir welding and hybrid friction diffusion bonding are investigated as technological welding processes in this paper.

Method and apparatus for electric arc welding

Abstract: An electric arc welding apparatus for depositing molten metal from an advancing welding wire into a weld puddle in an open root between two juxtapositioned plates where the root extends in a welding path and is formed by converging walls terminating in generally parallel walls spaced to define a gap, which apparatus comprises a contact holder with a wire outlet, a switching power supply directing welding current to the wire as the wire passes from the outlet toward the open root, with the advancing wire defining an electrode stick out between the contact holder and the weld puddle, a circuit for sensing the length of the stick out, and control means for adjusting the welding current as a function of the sensed stick out length.