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<p>The connection quality of multi-layer workpieces such as tabs and busbars is key to lithium-ion batteries. Electromagnetic pulse welding, as a solid-state welding technology, can be used for welding these workpieces for lithium-ion batteries. However, the gaskets required for electromagnetic pulse welding are inconvenient to place and remove in the multi-layer structure. This work proposed an electromagnetic pulse welding method based on a double H-type welding coil and gradient through hole. The flyer was used to weld the busbar by the Lorentz force through the gradient through a hole, and each Cu tab was connected at the same time. When the discharge voltage was 11&#xa0;kV, the metallurgical bonding of 1&#xa0;mm-thick Al flyer, 6 layers of 0.3&#xa0;mm-thick Cu tabs, and 1&#xa0;mm-thick Al busbar was realized. Scanning electron microscopy and energy dispersive spectroscopy analysis were carried out from the welding interface perpendicular to the welding direction and parallel to the welding direction. The results showed that the typical electromagnetic pulse welding morphology was formed in the welding interfaces. Different from the welding interface parallel to the welding direction, complex transient zones and some defects were found in the welding interface perpendicular to the welding direction. The metal jet generated by the impact between the flyer and the busbar formed an intermetallic compounds transition zone with Cu tabs. The tensile test showed that the bonding strength of the electromagnetic pulse welding joint was good.</p>

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A new strategy to electromagnetic pulse welding of multi-layer Cu tabs to Al busbar for electric vehicle battery

  • 期刊论文

  • 发表日期：

    2026年1月3日

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  • Yan Zhou,
  • Chengxiang Li,
  • Dan Chen,
  • Zhaoxiao Wu,
  • Yihang Shu,
  • Dan Li

摘要

The connection quality of multi-layer workpieces such as tabs and busbars is key to lithium-ion batteries. Electromagnetic pulse welding, as a solid-state welding technology, can be used for welding these workpieces for lithium-ion batteries. However, the gaskets required for electromagnetic pulse welding are inconvenient to place and remove in the multi-layer structure. This work proposed an electromagnetic pulse welding method based on a double H-type welding coil and gradient through hole. The flyer was used to weld the busbar by the Lorentz force through the gradient through a hole, and each Cu tab was connected at the same time. When the discharge voltage was 11 kV, the metallurgical bonding of 1 mm-thick Al flyer, 6 layers of 0.3 mm-thick Cu tabs, and 1 mm-thick Al busbar was realized. Scanning electron microscopy and energy dispersive spectroscopy analysis were carried out from the welding interface perpendicular to the welding direction and parallel to the welding direction. The results showed that the typical electromagnetic pulse welding morphology was formed in the welding interfaces. Different from the welding interface parallel to the welding direction, complex transient zones and some defects were found in the welding interface perpendicular to the welding direction. The metal jet generated by the impact between the flyer and the busbar formed an intermetallic compounds transition zone with Cu tabs. The tensile test showed that the bonding strength of the electromagnetic pulse welding joint was good.