Experimental Investigation of Mechanical Behaviour and Interface Morphology in Al/CuNi Ultrasonic Bonded Joints for Electric Vehicle Battery Tabs
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Abstract
The future of green and renewable technology is devoted to electric vehicles as these emit zero greenhouse gases and are environmentally friendly. Battery power and its energy density have a significant impact on the performance of these vehicles. These batteries are manufactured by joining multiple layers of dissimilar materials. The purpose of this research is to investigate the attributes of ultrasonic spot welding (USW) for joining dissimilar materials, notably aluminium (Al) and cupro-nickel (CuNi) sheets, through a comprehensive analysis of mechanical performance evaluation and microstructural characterisation at different weld parametric conditions. The joints tensile shear and T-peel strengths exhibited a progressive increase as the welding energy was raised. They peaked at 841 N and 271 N, respectively, before diminishing rapidly due to the elevated temperature at the weld interface. Furthermore, a micro-hardness measurement at the weld area revealed that Al-CuNi specimens had a higher hardness value than their base metals. According to the microstructural analysis, the bonding line seems almost straight at lower energy levels. Still, it diminishes as the energy levels increase because of the interdiffusion of the parent elements. Moreover, the results of an energy-dispersive X-ray spectroscopy (EDS) analysis of excellent weld conditions are also discussed.
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