High-brightness laser welding with beam wobbling: Achieving high-strength Al/Steel joints for battery busbars
Year: 2025
Type: article
Abstract: Laser welding of aluminium tabs to nickel-plated interstitial-free (IF) steel was investigated using a high-brightness, single-mode laser with beam wobbling. The influence of interaction time (controlled by wobble amplitude) and traverse speed (regulating energy distribution) on weld microstructure and mechanical properties was systematically studied. Short interaction times (<25 µs) and large inter-wobble distances (>150 µm) minimized intermetallic compound (IMC) formation and maximized weld strength. Optimizing these parameters (wider wobble amplitudes of 0.6–0.8 mm and faster speeds of 75–100 mm/s) suppressed IMC-induced cracking, resulting in microstructures containing Fe-rich IMCs and Al-Fe4Al13 eutectic phases. Conversely, lower wobble amplitudes (<0.6 mm) and slower speeds (50–75 mm/s) promoted crack-prone Al-rich Fe2Al5 phases. Optimized welds exhibited excellent fatigue performance, withstanding 1 million cycles at 175N, demonstrating the potential for using lighter, cost-effective aluminium busbars in battery interconnect applications.
Institution: University of Warwick
Language: English
Subfield: Mechanical Engineering
Field: Engineering
Domain: Physical Sciences
Open Access status: gold
Estimated APC paid: $2,410
OpenAlex ID: W4409868595