Laser Treatment Tailoring of Microstructure on Dissimilar Metal joints for improved EV performance (EV-DiMMeTTaL)

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Battery contact tabs form critical part in the assembly of batteries in Electric Vehicles (EV) and distributed electrical storage. The joints have strict requirements for reliability and electrical conductivity performance. This project explores multi-disciplinary work using lasers to enhance the performance and integrity of EV battery weld tabs. We aim to develop a hybrid three-step process combining surface preparation, joining and post-processing to accomplish cleaning, welding and post-peening for battery production. A novel pulsed green laser will be deployed for the cleaning and peening processes, while diode emitted high power blue laser will be used for the energy intensive welding process. The process will be automated, characterized, ranked and validated against existing welding and processing standards applied by the battery manufacturing industry. The developed process is expected to improve the performance of welded battery contacts, demonstrating higher conductivity, lower losses and improved reliability all supporting net zero waste initiative.