Microstructural analysis and optimization in laser-welded aluminum 1050 for battery interconnects

This study investigates the electrical resistance in laser-welded aluminum 1050A plates for battery manufacturing applications. Laser welding offers precise energy control and reduced thermal deformation [1], yet optimizing electrical resistance at optimal weld depths remains challenging [2]. A methodology integrating experimental analysis, numerical simulations, and optimization techniques was developed to achieve reduced resistance at optimal weld depths. Laser-welded aluminum plates underwent microstructural analysis using segmented micrographs. Finite element models were created with OOF2.0 for meshing, ANSA for refinement, and Abaqus for micro-electronic simulations. Correlation factor analysis linked electrical resistance, weld depth, and process parameters. Metamodels facilitated multi-objective optimization using the Pareto front and NSGA-II algorithm to minimize resistance and maximize weld depth. This approach provided insights into electric resistance variations within welded zones at optimal weld depths. The framework can improve electrical performance in laser-welded joints, supporting advancements in EV battery manufacturing and precision welding technologies.