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<p>The busbar, one of the electrical connectors in electric-vehicle battery packs, undergoes a process to form a terminal at its end (i.e., a termination). In this study, laser edge welding was performed on two types of busbars (round and square) for busbar termination, and the weld formation mechanisms and joint properties were analyzed. In the round busbar, the curved shape of the edge forms a groove, resulting in different welding characteristics compared with the square-type busbar, which has a flat edge. In round-type welding, the groove structure increased thermal interaction at the laser-material interface, producing a total weld depth 0.24&#xa0;mm greater than that of the square type; it also caused the grain growth direction to branch into two distinct paths. Additionally, cracks of approximately 100&#xa0;<InlineEquation ID="IEq1"> <EquationSource Format="TEX">\(\upmu \)</EquationSource> <EquationSource Format="MATHML"><math> <mi mathvariant="normal">μ</mi> </math></EquationSource> </InlineEquation>m size were sporadically observed in round-type welds; this effect was attributed to the constraint on shrinkage deformation imposed by the groove structure. The mean hardness of the square-type weld remained uniform at 63.74 HV, whereas the hardness in the round-type weld decreased to 28.8 HV in cracked regions. For both edge types, the electrical resistance of the joints decreased with increasing weld depth. However, the round-type joint exhibited the electrical resistance 2.4 <InlineEquation ID="IEq2"> <EquationSource Format="TEX">\(\upmu \Omega \)</EquationSource> <EquationSource Format="MATHML"><math> <mrow> <mi mathvariant="normal">μ</mi> <mi mathvariant="normal">Ω</mi> </mrow> </math></EquationSource> </InlineEquation> higher than that of the square type, as a result of differences in dislocation density of the base metal. This study also provides in-depth insights into the heat transfer mechanism of laser edge welding based on the geometric shape of the busbar, which is a decisive factor influencing welding characteristics.</p>

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Laser edge welding of thick Cu busbars for termination: role of edge shape

  • 期刊论文

  • 发表日期：

    2026年6月3日

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  • Seungwon Jeong,
  • Joonghan Shin

摘要

The busbar, one of the electrical connectors in electric-vehicle battery packs, undergoes a process to form a terminal at its end (i.e., a termination). In this study, laser edge welding was performed on two types of busbars (round and square) for busbar termination, and the weld formation mechanisms and joint properties were analyzed. In the round busbar, the curved shape of the edge forms a groove, resulting in different welding characteristics compared with the square-type busbar, which has a flat edge. In round-type welding, the groove structure increased thermal interaction at the laser-material interface, producing a total weld depth 0.24 mm greater than that of the square type; it also caused the grain growth direction to branch into two distinct paths. Additionally, cracks of approximately 100  \(\upmu \) μ m size were sporadically observed in round-type welds; this effect was attributed to the constraint on shrinkage deformation imposed by the groove structure. The mean hardness of the square-type weld remained uniform at 63.74 HV, whereas the hardness in the round-type weld decreased to 28.8 HV in cracked regions. For both edge types, the electrical resistance of the joints decreased with increasing weld depth. However, the round-type joint exhibited the electrical resistance 2.4 \(\upmu \Omega \) μ Ω higher than that of the square type, as a result of differences in dislocation density of the base metal. This study also provides in-depth insights into the heat transfer mechanism of laser edge welding based on the geometric shape of the busbar, which is a decisive factor influencing welding characteristics.