Effect of Weld Profile Geometry on Dissimilar Laser Welded Joints for Battery Applications.
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| Title: | Effect of Weld Profile Geometry on Dissimilar Laser Welded Joints for Battery Applications. |
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| Authors: | Sinhmar, Sunil1 (AUTHOR) sunil.sinhmar@pilani.bits-pilani.ac.in, Kumar, Pardeep1 (AUTHOR) p20240464@pilani.bits-pilani.ac.in, Mondal, K.2 (AUTHOR) kallol@iitk.ac.in |
| Source: | Journal of Materials Engineering & Performance. Mar2026, Vol. 35 Issue 12, p11931-11939. 9p. |
| Subjects: | Dissimilar welding, Laser welding, Electric resistance, Tensile strength, Battery management systems, Aluminum alloy welding, Corrosion engineering |
| Abstract: | A transition from fossil fuels to greener technologies like batteries is essential for a sustainable future. This study explores the impact of weld profile geometry on laser-welded aluminum–copper (Al–Cu) dissimilar lap joints at a constant power input of 2.1 kW, relevant for bus-bar connections in electric vehicle battery manufacturing. Two weld profiles: parallel line and circular, were compared in terms of microstructure, mechanical strength, electrical resistance, and corrosion behavior of the joints. Microstructural analysis showed that the circular weld exhibited deeper penetration and a wider Al2Cu intermetallic layer, while the parallel profile had a thinner, sharper, and uniform interface. Mechanical tests indicated that the circular profile achieved 66% higher peak load and better ductility. It also showed lower electrical resistance and reduced temperature rise under currents of 50 A, 100 A, and 150 A, suggesting improved conductivity than parallel line weld. However, electrochemical testing revealed higher corrosion current density and severe interfacial degradation in the circular profile due to its broader, uneven intermetallic zone. The findings emphasize that weld profile geometry significantly influences joint behavior, and optimized weld design can enhance performance without increasing power input, particularly relevant for battery interconnects and lightweight electronic applications. [ABSTRACT FROM AUTHOR] |
| Copyright of Journal of Materials Engineering & Performance is the property of Springer Nature and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.) | |
| Database: | Engineering Source |
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| Header | DbId: egs DbLabel: Engineering Source An: 192619702 AccessLevel: 6 PubType: Academic Journal PubTypeId: academicJournal PreciseRelevancyScore: 0 |
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| Items | – Name: Title Label: Title Group: Ti Data: Effect of Weld Profile Geometry on Dissimilar Laser Welded Joints for Battery Applications. – Name: Author Label: Authors Group: Au Data: <searchLink fieldCode="AR" term="%22Sinhmar%2C+Sunil%22">Sinhmar, Sunil</searchLink><relatesTo>1</relatesTo> (AUTHOR)<i> sunil.sinhmar@pilani.bits-pilani.ac.in</i><br /><searchLink fieldCode="AR" term="%22Kumar%2C+Pardeep%22">Kumar, Pardeep</searchLink><relatesTo>1</relatesTo> (AUTHOR)<i> p20240464@pilani.bits-pilani.ac.in</i><br /><searchLink fieldCode="AR" term="%22Mondal%2C+K%2E%22">Mondal, K.</searchLink><relatesTo>2</relatesTo> (AUTHOR)<i> kallol@iitk.ac.in</i> – Name: TitleSource Label: Source Group: Src Data: <searchLink fieldCode="JN" term="%22Journal+of+Materials+Engineering+%26+Performance%22">Journal of Materials Engineering & Performance</searchLink>. Mar2026, Vol. 35 Issue 12, p11931-11939. 9p. – Name: Subject Label: Subjects Group: Su Data: <searchLink fieldCode="DE" term="%22Dissimilar+welding%22">Dissimilar welding</searchLink><br /><searchLink fieldCode="DE" term="%22Laser+welding%22">Laser welding</searchLink><br /><searchLink fieldCode="DE" term="%22Electric+resistance%22">Electric resistance</searchLink><br /><searchLink fieldCode="DE" term="%22Tensile+strength%22">Tensile strength</searchLink><br /><searchLink fieldCode="DE" term="%22Battery+management+systems%22">Battery management systems</searchLink><br /><searchLink fieldCode="DE" term="%22Aluminum+alloy+welding%22">Aluminum alloy welding</searchLink><br /><searchLink fieldCode="DE" term="%22Corrosion+engineering%22">Corrosion engineering</searchLink> – Name: Abstract Label: Abstract Group: Ab Data: A transition from fossil fuels to greener technologies like batteries is essential for a sustainable future. This study explores the impact of weld profile geometry on laser-welded aluminum–copper (Al–Cu) dissimilar lap joints at a constant power input of 2.1 kW, relevant for bus-bar connections in electric vehicle battery manufacturing. Two weld profiles: parallel line and circular, were compared in terms of microstructure, mechanical strength, electrical resistance, and corrosion behavior of the joints. Microstructural analysis showed that the circular weld exhibited deeper penetration and a wider Al2Cu intermetallic layer, while the parallel profile had a thinner, sharper, and uniform interface. Mechanical tests indicated that the circular profile achieved 66% higher peak load and better ductility. It also showed lower electrical resistance and reduced temperature rise under currents of 50 A, 100 A, and 150 A, suggesting improved conductivity than parallel line weld. However, electrochemical testing revealed higher corrosion current density and severe interfacial degradation in the circular profile due to its broader, uneven intermetallic zone. The findings emphasize that weld profile geometry significantly influences joint behavior, and optimized weld design can enhance performance without increasing power input, particularly relevant for battery interconnects and lightweight electronic applications. [ABSTRACT FROM AUTHOR] – Name: AbstractSuppliedCopyright Label: Group: Ab Data: <i>Copyright of Journal of Materials Engineering & Performance is the property of Springer Nature and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.) |
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| RecordInfo | BibRecord: BibEntity: Identifiers: – Type: doi Value: 10.1007/s11665-025-12443-4 Languages: – Code: eng Text: English PhysicalDescription: Pagination: PageCount: 9 StartPage: 11931 Subjects: – SubjectFull: Dissimilar welding Type: general – SubjectFull: Laser welding Type: general – SubjectFull: Electric resistance Type: general – SubjectFull: Tensile strength Type: general – SubjectFull: Battery management systems Type: general – SubjectFull: Aluminum alloy welding Type: general – SubjectFull: Corrosion engineering Type: general Titles: – TitleFull: Effect of Weld Profile Geometry on Dissimilar Laser Welded Joints for Battery Applications. Type: main BibRelationships: HasContributorRelationships: – PersonEntity: Name: NameFull: Sinhmar, Sunil – PersonEntity: Name: NameFull: Kumar, Pardeep – PersonEntity: Name: NameFull: Mondal, K. IsPartOfRelationships: – BibEntity: Dates: – D: 25 M: 03 Text: Mar2026 Type: published Y: 2026 Identifiers: – Type: issn-print Value: 10599495 Numbering: – Type: volume Value: 35 – Type: issue Value: 12 Titles: – TitleFull: Journal of Materials Engineering & Performance Type: main |
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