Overview and details of the sessions of this conference. Please select a date or location to show only sessions at that day or location. Please select a single session for detailed view (with abstracts and downloads if available).
Please note that all times are shown in the time zone of the conference. The current conference time is: 27th Jan 2022, 10:22:13pm CET
Session Chair: Jakob R. Ermer, Bayerisches Laserzentrum GmbH (blz), Germany
11:15am - 11:30am
Laser in vacuum spot welding of electrical steel sheets with 3.7% Si-content
Thomas Krichel, Simon Olschok, Uwe Reisgen
Welding and Joining Institute, RWTH - Aachen University, Germany
The energy efficiency of electric motors is largely determined by the magnetic and electrical properties of the soft magnetic core material. For high-frequency applications in the automotive sector, the cores usually consist of iron-silicon alloys with several lamellae electrically insulated from each other to minimize eddy current loss. To join these lamellae, a novel method with individual, statistically distributed weld spots instead of continuous linear welds is used. The influence of beam power and beam intensity on the weld geometry, grain structure and torsional strength of the material is investigated.
11:30am - 11:45am
Solutions of laser material processing for electric mobility – evaluation of the Technology Readiness Level
Christoph Wunderling, Christian Bernauer, Christian Geiger, Korbinian Goetz, Sophie Grabmann, Lucas Hille, Andreas Hofer, Michael K. Kick, Johannes Kriegler, Lukas Mayr, Maximilian Schmoeller, Christian Stadter, Lazar Tomcic, Tony Weiss, Avelino Zapata, Michael F. Zaeh
Technical University of Munich, Institute for Machine Tools and Industrial Management, Germany
Battery technology and lightweight design are central fields of research and development when it comes to making electric mobility technically and economically attractive for producers and customers. In this context, laser material processing will be a driver to enable innovations in future product generations. For this reason, the publication addresses the most relevant laser-based production technologies that are currently being researched or about to be transferred to applications in electric mobility. In order to give a structured and uniform overview, the advantages of individual processes are mentioned and the technology-specific state of the art is quantitatively presented based on a methodical procedure for the evaluation of the Technology Readiness Levels. Upon this, the challenges for the deployment in industrial production are specified, which is the basis to describe the need for adaption and further development in laser material processing
11:45am - 12:00pm
System and process development for functionalization of electrical components by laser-based gold micro deposition
Tobias Schmid1, Henning Janssen1, Christian Brecher1,2
1Fraunhofer Institute for Production Technology IPT, Germany; 2Laboratory for Machine Tools and Production Engineering (WZL) of RWTH Aachen University
During the manufacture of electrical contact components, the contacts are coated with precious metals. Currently, energy- and resource-intensive electroplated coatings are used. A sustainable alternative is the local functionalization of sheet parts using small gold spots with the appropriate system technology for laser-based micro wire deposition. However, the necessary process reliability and required short cycle times represent a challenge for the technology. Within this paper, the system development of a stand-alone coating system is described. The approach presented is based on a laser beam deflection unit, fully automatic laser system control, a 5-axis wire head and a quality assurance system. An analysis of the deposition results was carried out, taking into account crucial process parameters. The resource efficiency study shows significantly reduced gold usage through local sustainable coating. Almost 100% material utilization is achieved, while gold spots geometry and position can be adjusted and replace the full surface electroplating coating.
12:00pm - 12:15pm
Laser technologies for battery pack production
The global mobility revolution is in full swing. The demand for components for electric cars and alternative drives is rising continuously. Many production approaches are making use of the benefits of laser technologies. It connects battery cells to form modules or packs. It ensures tightness and crash safety when joining battery packs and trays.
This paper offers an insight into the requirements of battery packs as well as the innovative joining technology solutions for the material specifics, which are made possible by the use of novel laser and system developments in industrial practice. Furthermore, the trends of future battery packs will be presented. Finally, a spotlight will present the next generation of laser and joining technologies for use in battery system manufacturing and place them in the context of existing material-specific challenges, such as helium-tight welding of aluminum alloys.
12:15pm - 12:30pm
Contacting of cylindrical lithium-ion batteries using short pulse laser
Lukas Mayr, Lazar Tomcic, Michael K. Kick, Christoph Wunderling, Michael F. Zaeh
Technical University of Munich, Institute for Machine Tools and Industrial Management, Garching, Germany
The increasing demand for electric vehicles requires innovative manufacturing processes to improve the electrical performance and decrease the production costs of energy storages. Laser beam welding (LBW) is a highly flexible and fast process for connecting multiple battery cells automatically. Highly electrical conductive materials such as copper and aluminum are challenging in terms of LBW. A possibility to overcome these challenges, such as the high reflectivity and thermal conductivity, is the use of nanosecond laser pulses with peak powers up to several kilowatts. In experiments, this process was found to achieve narrow welds with high aspect ratio and low heat input. Beam oscillation was investigated in order to widen the weld seams and enhance the electrical conductivity and mechanical strength. This study shows the proof of concept and parameter investigation for the use of short pulse LBW for difficult to weld lap joints containing copper and aluminum or hilumin.