A multi-physics CFD study on the part-to-part gap during remote laser welding of copper-to-steel battery tab connectors with beam wobbling

Remote Laser Welding (RLW) of dissimilar metallic thin foils (below 500 µm) has fundamental importance in battery pack manufacturing where high repeatability is a strict requirement. Since the welding process very sensitive to part-to-part gaps, it critical understand physical phenomena during melting, formation keyhole and solidification. This study been designed investigate underlying physics influence laser beam wobbling gap on temperature fields metal mixing. A CFD multi-physics model implemented then calibrated with experimental data. Two scenarios (0 100 have considered lap 300 µm copper nickel-plated steel, circular wobbling. The highlighted that leads uncontrolled Potential strategies for weld optimization are discussed throughout paper.