The current state of research on charge-weld material integrity in aluminum extrusion reveals a significant knowledge gap, particularly in understanding how the deformation history and mechanisms related to the charge weld zone affect the mechanical integrity and properties of the product.
Welding is a vitally important family of joining techniques for EV battery systems. A large battery might need thousands of individual connections, joining the positive and negative terminals of cells together in combinations of parallel and series blocks to form modules and packs of the required voltage and capacity.
Charge weld is a solid-state pressure weld between the mating surfaces of two successive billets . In an ideal scenario, where the merging surfaces of both billets have no aluminum oxide layer and exhibit identical mechanical properties, the configuration could be classified as non-defective .
The charge weld formation within the extrusion die was calculated up to the point where new material reached the bearing surface area using the velocity of each tracked point, as shown in Fig. 11. The gradual formation of the charge weld was illustrated based on this computation with a time interval of 0.3 s.
Drift-expanding experiments reveal that the fracture initiation size is more substantial in the early-stage compared to the mid-stage of charge weld progression under a hoop strain of 0.6 mm/mm, without obvious fracture initiation detected in the late-stage.
“We see a lot of laser welding and ultrasonic wedge bonding for the larger packs,” says Boyle at Amada Weld Tech. “If the packs or the overall volume are smaller, then resistance welding is often used. Micro-TIG comes up for specialised battery packs with low-volume production.
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