Laser Welding for Battery Poles & Terminals: The "Zero-Spatter" Guide
Release time:
2025-11-26
Battery Pole Welding (also referred to as Terminal Welding) is the critical process of joining busbars to cell terminals with high-precision lasers, using adjustable Beam Profile (ABP) technology. Our ABP controls allow independent control over central core beam penetration and outer ring beam spatter suppression ensuring zero defects for every connection we weld.
Battery Pole Welding (also referred to as Terminal Welding) is the critical process of joining busbars to cell terminals with high-precision lasers, using adjustable Beam Profile (ABP) technology. Our ABP controls allow independent control over central core beam penetration and outer ring beam spatter suppression ensuring zero defects for every connection we weld.
Battery Pole Weld is the heart of battery module assembly. A poor weld here results in increased resistance and heat production, while welds directly over live cells carry an enormous risk of burn-through (puncture) and spatter (contamination).
Here is how we have designed our process to guarantee integrity without jeopardizing the cell.
1. The Penetration Paradox: Why "Wobble" Isn't Enough
Strong welding requires deep penetration; yet electrolyte lies only millimeters away. Standard wobble heads mechanically stir the melt pool but don't alter energy distribution at the source.
Solution: Adjustable Beam Profile (ABP) Technology.
Instead of mechanically shifting the beam, we utilize Active Beam Shaping source.
The Ring Beam (Outer): Preheats and stabilizes the melt pool, maintaining an open keyhole.
The Core Beam (Center): Provides high-intensity energy needed for deep penetration.
Results: Our "Core-in-Ring" architecture decouples penetration depth from spatter generation, enabling us to weld battery poles with no risk of puncture and an extended process window.
2. Solving the "Spatter" Nightmare
Spatter is the enemy of high-voltage systems. Even one micron-sized metal ball can cause an electrical short circuit.
Engineering Solution: "Spatter-Free" Power Distribution
Standard fiber lasers cause rapid changes in vapor pressure that lead to spatter. Our ABP system offers a solution by controlling both Core and Ring powers independently for greater control.
By setting a specific power ratio (e.g., 40% Ring/60 Core), a Ring beam creates a safe "buffer zone" around its keyhole to suppress capillary instability which causes ejection; thus providing an effective spatter-free surface essential for high voltage insulation safety.
3. Dissimilar Metals: Cu-Al Joining
Many designs call for welding copper busbars onto aluminum poles.
Problem: Brittle intermetallic compounds (IMCs).
Expertise: The uniform energy distribution provided by ABP Ring Mode creates a more uniform melt pool when compared with Gaussian beams, effectively controlling Dilution Rate and keeping IMC layers thin ( 10um) and ductile.
4. Troubleshooting Guide: Common Weld Defects
Engineer's Troubleshooting Matrix
|
Defect Phenomenon |
Root Cause (Physics) |
Huiyao Solution (Parameter) |
|
Burn-Through |
Heat Input ($Q$) too high |
Reduce Core Power, Increase Ring Width |
|
Spatter / Ejection |
Unstable Keyhole collapse |
Increase Ring Power ratio to stabilize |
|
Cracking (Al-Cu) |
IMC layer too thick |
Optimize Ring/Core mixing ratio |
|
Porosity |
Vapor trapped in pool |
ABP modulation allows gas escape |
Validated Safety
Don't gamble with battery poles. Our lines include Real-time Seam Tracking for 100% safety.
Solution: Dual-Station Laser Welding Machine
AUTHOR:
The Huiyao Laser Engineering Team :A collective of solution architects and process engineers at Huiyao Laser, 100% dedicated to solving the core bottlenecks in EV and ESS battery manufacturing.
© 2025 Huiyao Laser Technology Co., Ltd. All Rights Reserved.No part of this content (including text, data tables, or original diagrams) may be reproduced without written permission.
key word:
Dual-Station Laser Welding Machine,Laser Welding for Battery Poles & Terminals
