The EV market is zipping ahead. The “Electric Vehicles: Global Strategic Business Report” estimates the global market for EVs will reach 80.7 million units by 2030, growing at a CAGR of 30.7% over the analysis period 2022-2030.
The battery pack is the heart of the EV. It is what releases these vehicles from their dependence on fossil fuels. Now, these battery packs are formed of an intricate network of cells. The most popular battery pack supplied by Tesla, for instance, contains around 7000 cells capable of storing 85 kWh of energy. One defective connection can result in failure.
This brings us to joints, which are what keep the battery together. The quality of the joint is what decides the sustainability and safety of EVs and it is what prevents failure or accelerated aging of the vehicle.
Laser welding is the most promising technology to contact battery cells in EVs. It enables fast and precise production of joints primarily because they have a reduced thermal energy input as temperature increase may be harmful to lithium-ion battery cells.
According to a 2022 study titled ‘Quality assurance of battery laser welding’, low electrical resistance and high mechanical strength are key advantages of laser welding compared to other welding processes.
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