An investigation of mechanical and electrical properties of friction stir welded Al and Cu busbar for battery pack applications

The aluminum and copper (Al–Cu) busbar is widely used as a core component in Lithium-Ion (Li-ion) batteries. Al–Cu challenging to fabricate with the traditional welding processes because of its high thermal conductivity. fabricated using friction stir method present study. effect temperature vibration generated during process on intermetallic compounds (IMCs) studied effective formation model found that Al2Cu first form at interface. IMC joint interface had detrimental (Al-rich IMC) beneficial (Cu-rich effects. presence IMCs affects strength about 36% compared sample highest tensile load. surface electrical conductivity measured by Gaussian profile range 0.94–5.37 μ Ω·mm. welded samples Al2Cu3 Al4Cu9 are have higher Interestingly, load observed due Cu-rich IMC, i.e., Al4Cu9.