Fantastic Results with Ultrasonic assisted laser welding for high volume assembly of automotive battery packs

Contactless Transducers for PUVT (Power Ultra-Sound Vibration Treatment) were designed, tested and proved to work. This is the major achievement for Soni-Laser as this means PUVT is possible in production.
Aluminium, to Aluminium, welds with PUVT are more than 10% stronger and have improved extension prior to fracture, in cases up-to 64% improved extension prior to fracture. Proved on all the aluminium grades normally used in battery interconnection.
Copper to Aluminium welds are more than 10% on average stronger and up-to 22% stronger in cases. PUVT improved the extension, but it is still not an advised weld for a battery/busbar connection. It’s too brittle and prone to fracture.
Connection Impedance of Aluminium welds with PUVT showed a small reduction of impedance of typically 5%.
SEM analysis shows in the copper/aluminium weld a more uniform composition in the aluminium rich region when applying ultrasounds.
SEM analysis shows that the PUVT reduces the spread of the copper into the fusion zone, thus reducing the intermetallic compounds in the aluminium rich region.