Article
Materials Science, Multidisciplinary
Marcus Glaser, Sebastian Matthes, Joerg Hildebrand, Jean Pierre Bergmann, Peter Schaaf
Summary: Multi material pairings, such as metal-plastic hybrids, are increasingly important in various industries. However, substituting metals with plastics presents numerous challenges due to the combination of dissimilar materials. This study investigates the joining process between semi-crystalline polyamide 6 and austenitic stainless steel X5CrNi18-10 using reactive Al/Ni multilayers. The focus is on evaluating the joint strength and understanding the failure behavior and binding mechanisms at the fracture interface under tensile load.
MATERIALS & DESIGN
(2023)
Article
Automation & Control Systems
Joon Ho Cha, Hae Woon Choi
Summary: Laser welding offers many advantages in the manufacturing of EV battery packs, with the ability to optimize results and tensile strength by adjusting output ratios and other conditions. Increasing power may widen weld seams and form small pores, but penetration depth does not significantly change.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Article
Engineering, Manufacturing
Yidi Wu, Huihong Liu, Yongbing Li
Summary: A novel resistance welding method called RRW was developed for long-distance, large-area, and multiple-layer Al-Cu welding. Al layers were joined by Al2Cu intermetallic compound generation and dynamic recrystallisation mechanisms, and the influence of welding current on joint load and resistance showed a similar trend. A sound dissimilar joint with high coach-peel load and relatively lower resistance was obtained via RRW.
JOURNAL OF MANUFACTURING PROCESSES
(2022)
Article
Electrochemistry
Martina E. Sigl, Sophie Grabmann, Luca-Felix Kick, Amanda Zens, Roman Hartl, Michael F. Zaeh
Summary: This paper presents a new approach for cell-internal contacting by using micro-friction stir spot welding, which can achieve high-quality and high-strength connections. The experiments showed that large stacks of battery cells can be joined in a short period of time. This method is particularly important for the fast production of large-scale battery cells or other types of high-energy-dense battery cells.
Article
Materials Science, Multidisciplinary
Seungmin Shin, Sangwoo Nam, Jiyoung Yu, Jiyong Park, Dongcheol Kim
Summary: This study analyzed the application of UMW technology in lithium-ion battery cells, investigating the impact of alignment on welding quality and the effects of various process parameters on welding performance.
Article
Electrochemistry
Wei Qin, Yuanbo Chen, Jie An, Jun Zhang, Xiaogang Wen
Summary: A high-loaded porous nanobelt-constructed multilayer hierarchical Li4Ti5O12 nanostructure and N-doped NBMH-LTO electrode were successfully prepared via hydrothermal and vapor-solid reaction processes. These materials exhibited excellent performance in lithium ion batteries, making them promising electrode materials.
ELECTROCHIMICA ACTA
(2022)
Article
Mechanics
Jia-Ming Chang, Kam-Hong Kam, Yu-Jun Liu, Nitika Devi, Tsung-Ying Tsai, Kun-Tso Chen, Pai-Chen Lin
Summary: This study examined the fatigue behavior of laser-welded lap-shear samples in copper sheets of different thicknesses using experimental and numerical methods. Experimental results showed interfacial failure under high-load and low-load conditions, as well as top sheet separation under medium-load conditions. Finite element analyses were conducted to calculate stress intensity factors for interfacial and kinked cracks. Two fatigue models were derived based on these factors and the Paris law to analyze the crack evolution and estimate fatigue lives. The predicted fatigue lives were in line with the experimental trends.
ENGINEERING FRACTURE MECHANICS
(2023)
Article
Engineering, Industrial
Qiuchen Ma, Yichen Cao, Wenwu Zhang, Weiwei Zhao, Hongtao Chen, Mingyu Li, Zhimin Liang, Yong Xiao, Hongjun Ji
Summary: The addition of Cu nanoparticles in ultrasonic welding significantly increased load carry capacity and reduced energy input. The Cu NPs facilitated material flow, accelerated elemental diffusion, and grain refinement, enhancing dynamic recrystallization in the base metal.
JOURNAL OF MATERIALS PROCESSING TECHNOLOGY
(2021)
Review
Chemistry, Multidisciplinary
Melissa L. Meyerson, Philippe E. Papa, Adam Heller, C. Buddie Mullins
Summary: Forty years after the failed introduction of rechargeable lithium-metal batteries and 30 years after the successful commercialization of the lower capacity, graphite-anode based lithium-ion battery by Sony, demand for higher energy density batteries is leading to reinvestigation of the problem of dendrite growth that makes the metallic lithium anodes unsafe. One strategy to mitigate dendrite growth is to deposit thin, tailored, corrosion-passivating coatings on the metallic lithium, instead of allowing the metal to spontaneously react with the organic electrolyte solution to form its passivating solid electrolyte interface (SEI).
Article
Metallurgy & Metallurgical Engineering
Arnout Dejans, David Moens, Patrick Van Rymenant
Summary: Leveraging the transition to carbon neutrality, the manufacturing industry is shifting towards multi-material structures to optimize costs and enable lightweight design, especially in automotive production. Joining dissimilar materials, such as steel and aluminum alloys, and copper and aluminum alloys, has proven to be a challenge due to discrepancies in physical and metallurgical properties. This study presents a novel resistance welding process, called locked projection welding, which combines metallurgical and mechanical connections to achieve a ductile joint failure, as opposed to the brittle failure exhibited by traditional resistance spot welds.
WELDING IN THE WORLD
(2023)
Article
Chemistry, Multidisciplinary
Dawei Yang, Mengyao Li, Xuejiao Zheng, Xu Han, Chaoqi Zhang, Jordi Jacas Biendicho, Jordi Llorca, Jiaao Wang, Hongchang Hao, Junshan Li, Graeme Henkelman, Jordi Arbiol, Joan Ramon Morante, David Mitlin, Shulei Chou, Andreu Cabot
Summary: This study proposes a method of adding copper selenide nanoparticles to the cathode of lithium-sulfur batteries to trap soluble lithium polysulfides and accelerate the reaction kinetics. By adjusting the crystal phase and defect density of the copper selenide, the electronic structure, affinity toward lithium polysulfides, and electrical conductivity can be controlled, resulting in improved battery performance.
Article
Materials Science, Multidisciplinary
Baolei Wu, Weiyuan Yu, Zhen Hu, Xuemin Sun
Summary: An FCC + BCC dual-phase solid solution structure high-entropy alloy (HEA) joint was successfully formed during self-propagating brazing using an Al/Ni nano-multilayer. The interdiffusion of atoms at the joint resulted in the formation of a solid solution zone. The joint exhibited improved shear strength and a transition from cleavage fracture to ductile fracture with the increment of external pressure.
MATERIALS CHARACTERIZATION
(2023)
Article
Materials Science, Multidisciplinary
Jingwei Zhao, Peichen Wang, Linan Ma, Zhubo Liu, Zhengyi Jiang, Leszek A. Dobrzanski, Chong Soo Lee, Xiaoguang Ma
Summary: The forming process of microchannels on copper foils was studied using micro rolling. It was found that annealing at 500 degrees C resulted in microchannels with high surface quality. Electron backscatter diffraction tests showed that the high forming accuracy of microchannels annealed at 500 degrees C was mainly due to the high geometric dislocation density. Optimizing the heat treatment process weakened the major texture components and improved the forming accuracy of microchannels.
MATERIALS CHARACTERIZATION
(2023)
Article
Energy & Fuels
Alexander Olowinsky, Christoph Spurk, Johanna Helm, Arnold Gillner
Summary: Battery technology is vital for the future of sustainable electric mobility, especially lithium-ion batteries in the automotive industry. To meet the growing demand, it is important to have efficient and cost-effective processes for battery cell production. The article discusses the development of laser-based electrode stack contacting for lithium-ion battery cells, focusing on using laser beam welding to join aluminum and copper electrodes within a short time.
Article
Engineering, Manufacturing
Zunnong Ma, Cheng Luo, Yansong Zhang
Summary: In this study, an efficient and accurate finite element model was proposed to simulate the ultrasonic spot welding process of multi-layer Cu or Al tabs. By introducing the interface heat flux, the heat generation caused by friction was effectively equivalent. The validated model was then applied to simulate the welding process of different layers of copper and aluminum foils, revealing that the heat generation concentrated in the middle interfaces and was related to welding parameters, tip size, and specimen structure.
JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING-TRANSACTIONS OF THE ASME
(2022)