Abstract: Ultrasonic welding is a solidstate bond created using ultrasonic energy. It has been used in the semiconductor industry for several decades, and more recently, in the automotive industry such as for lithiumion battery ...

Abstract: Ultrasonic metal welding is widely used for joining multiple layers of dissimilar metals, such as aluminum/copper battery tabs welding onto copper busbars. It is therefore important to have a robust product/process design ...

Abstract: Ultrasonic metal welding (USMW) for battery tabs must be performed with 100% reliability in battery pack manufacturing as the failure of a single weld essentially results in a battery that is inoperative or cannot deliver ...

Abstract: The fatigue life of ultrasonically welded lithiumion battery tab joints is studied for electric and hybrid–electric vehicle (EV and HEV) applications. Similar to metallic materials, the electrical resistance of these ...

Abstract: Spot weld layout is critical to structural performance of vehicle and its design is also subject to manufacturing constraints. In this study, using thinwalled tube crash as an example, we establish the relation between ...

Abstract: Resistance spot welding (RSW) of aluminum–aluminum (Al–Al) is known to be very challenging, with the asymmetric growth of the weld nugget often observed. In this article, a semicoupled electrical–thermal–mechanical finite ...

Abstract: Multilayered ultrasonic welding (USW) is widely used in joining of electrodes or tabs in lithium-ion batteries. To achieve quality joints and enhance the welding process robustness, an improved understanding of the joint ...

Abstract: This paper aims at providing a state-of-the-art review of an increasingly important class of joining technologies called solid-state (SS) welding, as compared to more conventional fusion welding. Among many other advantages ...

Abstract: Ultrasonic metal welding has been used to join multiple layers of battery tabs with the bus bar in lithium-ion battery assembly operations. This paper describes joint performance models for ultrasonic metal welds of multiple ...

Abstract: One of the major challenges in manufacturing automotive lithiumion batteries and battery packs is to achieve consistent weld quality in joining multiple layers of dissimilar materials. While most fusion welding processes ...