Energy storage welding is easy to fall off

How does resistance spot welding work?

When using resistance spot welding, careful consideration of the current path between the electrodes must be considered. The electrons will always flow along the path of least resistance, thus as the tabs get thicker, the energy will travel directly between the electrodes with little to no energy at the desired interface.

How long does it take to weld a battery pack?

For a battery pack consisting of 117 Cells (9 x 13), this means there are 234 sites to weld and total process time of 514.8 seconds. Since laser welding is a non-contact process, the only motion is making a weld pattern and the motion moving the beam from cell to cell. The weld cycle time is a combination of shots and small motion on a cell.

How does resistance welding work?

Resistance welding is essentially a self-tooling process; the electrodes come down on the parts forcing them into intimate contact. There are limitations to the amount of gap, but generally this is the easiest of the technologies in this regard. Tooling is generally still required to hold multiple parts in place.

Can a conductive material be used as a weld?

When the material is conductive – like aluminum or copper – this technology is not suitable. Some novel alloys which combine both resistive and conductive material are starting to be used – like Ni SS Cu (SIGMAclad®), – which provide a resistive layer to make the weld and a conductive layer to meet the challenges above.

Is laser welding a fusion welding process?

In general, laser welding is also a fusion welding process. However, new laser sources make it possible to avoid the traditional fusion process and join materials with limited intermetallic mixing. The resulting mechanical joint which is akin to Velcro®, provides good electrical and thermal contact.

Is micro TIG welding a fusion welding process?

Micro TIG welding is strictly a fusion process, which limits materials to be joined to those with compatible chemistries: welding copper to steel is possible, but aluminum to steel is not. In general, laser welding is also a fusion welding process.