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<p>There is a growing trend toward replacing conventional wire harnesses with flexible flat cables (FFCs) in cell contact systems (CCS), owing to their thin and narrow form factor enabling space-efficient, light battery pack design, and cost savings. This study investigates the process sensitivity of 532&#xa0;nm continuous-wave laser micro-dissimilar welding between an ultra-thin copper FFC and an uncoated Al1050 busbar for EV battery management systems (BMS). Six welding conditions were established at a fixed linear energy density (LED = 2&#xa0;J/mm) by varying laser power and scan speed from 500&#xa0;W to 250&#xa0;mm/s to 1000&#xa0;W and 500&#xa0;mm/s. Despite identical LED, weld quality varied markedly with the power–speed combination. At higher power conditions (≥ 700&#xa0;W), extensive cracks, pores, and Al–Cu intermetallic compound (IMC) layers raised electrical resistance up to 1205 µΩ. The low-power condition (600&#xa0;W and 300&#xa0;mm/s) produced the thinnest IMC layer (~ 10&#xa0;μm), the largest grain size, and the lowest electrical resistance (78 µΩ). Although defect-free three welding conditions passed the peel test, electrical resistance varied from 78 to 145 µΩ, inducing a non-negligible voltage offset at the BMS cell-sensing point. From these results, multi-criteria evaluations such as integrating mechanical integrity, electrical resistance, and microstructural analysis are needed for reliable laser micro-welding of ultra-thin dissimilar FFC-to-busbar joints.</p>

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Multi-Criteria Reliability Qualification on Laser Micro-Dissimilar Welding of Ultra-Thin Flexible Flat Cu Cable onto Uncoated Aluminum alloy Busbar for EV Cell Sensing

  • 期刊论文

  • 发表日期：

    2026年8月3日

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  • Hyunjong Yoo,
  • Doyun Ahn,
  • Minseok Lee,
  • Donghyun Kim,
  • Dongil Lee,
  • Eunho Kim,
  • Ik-Seon Kwon,
  • Hyun-Seop Kim,
  • Geum-Su Yeom,
  • Jihun Kim,
  • Hee-Shin Kang,
  • Junsu Park

摘要

There is a growing trend toward replacing conventional wire harnesses with flexible flat cables (FFCs) in cell contact systems (CCS), owing to their thin and narrow form factor enabling space-efficient, light battery pack design, and cost savings. This study investigates the process sensitivity of 532 nm continuous-wave laser micro-dissimilar welding between an ultra-thin copper FFC and an uncoated Al1050 busbar for EV battery management systems (BMS). Six welding conditions were established at a fixed linear energy density (LED = 2 J/mm) by varying laser power and scan speed from 500 W to 250 mm/s to 1000 W and 500 mm/s. Despite identical LED, weld quality varied markedly with the power–speed combination. At higher power conditions (≥ 700 W), extensive cracks, pores, and Al–Cu intermetallic compound (IMC) layers raised electrical resistance up to 1205 µΩ. The low-power condition (600 W and 300 mm/s) produced the thinnest IMC layer (~ 10 μm), the largest grain size, and the lowest electrical resistance (78 µΩ). Although defect-free three welding conditions passed the peel test, electrical resistance varied from 78 to 145 µΩ, inducing a non-negligible voltage offset at the BMS cell-sensing point. From these results, multi-criteria evaluations such as integrating mechanical integrity, electrical resistance, and microstructural analysis are needed for reliable laser micro-welding of ultra-thin dissimilar FFC-to-busbar joints.