National Projects
Research on the development of material joining techniques for battery pack fastener components (CellWeld)
Title:
Research on the development of material joining techniques for battery pack fastener components (CellWeld)
Acronym:
CellWeld
Name of the programme: Targeted Grants
Co-financing for Łukasiewicz – GIT from the funds of the Łukasiewicz Centre: PLN 850,050.00
Total value of the project: PLN 1,860,750.00
Start: 07.07.2021 / End: 31.10.2023
Consortium:
- Łukasiewicz Research Network – Upper Silesian Institute of Technology [Leader]
- Łukasiewicz Research Network – Institute of Non-Ferrous Metals
- Łukasiewicz Research Network – Tele and Radio Research Institute
Project Manager:
Krzysztof Kwieciński, BEng, MSc
Tel.: 32 33 58 304
E-mail: krzysztof.kwiecinski@git.lukasiewicz.gov.pl
Objective:
The subject of the project is the selection and development of technology for connecting battery cells and accumulators intended for modern electric cars. The technologies proposed for development, such as ultrasonic and resistance welding, laser beam welding, electron beam welding as well as microplasma and TIG welding, will allow to optimise the production process of Polish batteries.
The ultrasonic welding process will be carried out on a Łukasiewicz-ITR Sonic Welder ultrasonic welding machine using ultrasonic systems (Sonic Blaster generators, Sonic Converter ultrasonic converters, Sonic Boosters and dedicated ultrasonic sonotrodes). As part of the project, five dedicated tools for welding packages with different weld contour shapes will be created. FEM simulations of mechanical wave distribution in welded details will be performed.
The laser beam welding process will be carried out on a station equipped with a TruPulse 103 pulse laser, enabling classical laser welding with a pulse beam, and a single-mode laser welding station with a system for measuring fusion depth.
The electron welding process will be carried out on an XW150:30/756 electron device intended for welding and surface modification. The plasma welding process will be carried out on a station equipped with MSP 51 and Eu Tronic Gap 3001, and TIG welding – with ARISTOTIG IG 160 DC (Kemppi).
The process parameters of the processes will be recorded during the joining and welding process tests. Optimisation of joining techniques of materials intended for fasteners of battery packs will also require the development of numerical models of joining and welding processes for selected configurations of joined components and their verification.
The SysWeld and Sorpas environments will be used to build numerical (thermal) models enabling modelling of temperature fields. The final result of the task will be complete numerical (thermal) models, allowing to determine the temperature of the joined components depending on the technological conditions of welding and welding processes characteristic for a given process. The obtained models will enable the development of final joining technologies for the selected fasteners in terms of geometric dimensions and construction materials used.
All tasks will be performed in cooperation by Łukasiewicz Research Network – Upper Silesian Institute of Technology, which has equipment to carry out welding and welding processes, by Łukasiewicz Research Network – Tele and Radio Research Institute, which has an ultrasonic welding machine, and by Łukasiewicz Research Network – Institute of Non-Ferrous Metals, Central Laboratory of Batteries and Cells, where advanced equipment for structural and mechanical testing and physical properties testing of connectors are located.
