Electro-Thermo-Mechanical Integrity of Electric Vehicle Battery Interconnects Using Micro-TIG Welding

The fabrication of welded joints in steel sheets has become a focal point, especially in meeting the demands for interconnections within battery packs for electric vehicles (EVs). This study delves into the impact arising from the initiation arc during the micro-tungsten inert gas (TIG) welding of nickel-plated steel sheets. The investigation involved the manipulation of various current modulations and arc lengths. Notably, optimal results were achieved with a 5 mm arc length paired with a 25 A current modulation. Microstructural analysis, conducted through scanning electron microscopy (SEM), unveiled a higher penetration depth, contributing to a more extensive and shallower fusion zone at the interface between the filler metal and the base material. Tensile testing revealed impressive mechanical properties, with the ultimate tensile strength peaking at 90 N/mm2, a yield strength of 85 N/mm2, and the highest elastic modulus. This underscores the weld’s robustness in withstanding applied loads and resisting fracture. Furthermore, the calculation of the lowest K factor at 1.0375 indicated a reduction in resistance across the specimen, resulting in enhanced conductivity. Micro-TIG welding emerges as an efficient method for nickel-plated steel in connecting individual battery cells to form a high-capacity battery pack. These interconnections ensure efficient current flow and maintain the overall integrity and performance of the battery pack. The reliability and quality of these interconnects directly affect the battery’s efficiency, safety, and lifespan in EVs application.