Laser wobble welding of steel to Aluminium busbar joints for Li-ion battery packs

• Laser wobble welding of thin Steel tabs to thick Aluminium busbar for Lithium-ion battery packs. Weld geometry, microstructure, mechanical strength, and electrical contact resistance investigated. Development optimum laser-wobble parameters achieve high properties. A new joining solution cost-effective aluminium busbars in Electric Vehicle manufacturing. In this work, joints was investigated Li-ion pack applications. The effect amplitude on the properties weld studied. It is observed that significantly influenced resistance. As increases depth reduces linearly severity cracking reduced. Welds with an aspect ratio below 1, produce almost a crack-free microstructure. found be 0.8–1 mm selected laser power density. Under parametric conditions, strength reaches 1 KN, equalling steel sheet. addition, welds showed low volume intermetallic phase formation which improved both conductivity tensile strength. results study facilitate effective material steel-cased cylindrical cells.