Review on Laser Welding Technology on Aluminum and Copper Dissimilar Materials for Secondary Batteries Assembly

Abstract

Electric vehicles have recently taken center stage, driven by growing environmental concerns, with a key focus on ensuring the reliability of their batteries. The materials used in the electrical connections of secondary batteries predominantly consist of Al and Cu alloys, necessitating the joining of both similar and dissimilar materials. This paper presents a technical review on laser welding technology applied to the challenging Al/Cu dissimilar metal combination. The complexity arises from the formation of brittle phases in intermetallic compounds and the low absorption of laser beams by the base materials. The characteristics of various laser welding modes and their effective monitoring through deep learning are explained in detail. The development of real-time laser welding monitoring technology is crucial to increase productivity and enable the mass production of reliable electric vehicle battery systems.