Laser dissimilar welding of highly reflective materials for E-Mobility applications

Manufacturing technologies for E-Mobility applications have gained undoubted interest over recent years due to a large consensus towards hybrid and electric vehicles that characterize modern automotive requirements. Among the various components that make up an electric vehicle, batteries and electric motors represent the “heart” of this new class of transport and, given their constituting materials, require new and strategic manufacturing processes. With particular reference to joining processes, both batteries and electric motors require the application of welding techniques capable of dealing with lightweight and electrically conductive metals such as aluminum and copper alloys, often in dissimilar configurations. Among modern welding technologies, laser-based ones have proven to be a suitable solution both in low- and high-productivity environments. Within this context, the present chapter provides a comprehensive review of laser-based joining techniques for battery and electric motor production in the field of E-Mobility, giving an overview of what to expect in terms of equipment, results, challenges and limitations. Analysis of the state of the art in these applications is developed based on two main parameters: the wavelength and temporal profile of the radiation. In line with this distinction, applications of infrared, green and blue laser sources are considered, together with continuous-wave, long-pulse and short-pulse regimes.