A comprehensive Study on the Optimization of Laser Welding Process Parameters for Electric Vehicle Battery Interconnections

A comprehensive Study on the Optimization of Laser Welding Process Parameters for Electric Vehicle Battery Interconnections | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article A comprehensive Study on the Optimization of Laser Welding Process Parameters for Electric Vehicle Battery Interconnections Aygen Ahsen Yıldırım, EROL FEYZULLAHOĞLU, Rıdvan Yamanoğlu This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-7092430/v1 This work is licensed under a CC BY 4.0 License Status: Under Review Version 1 posted 5 You are reading this latest preprint version Abstract This study explored the application of laser welding for joining aluminum and Hilumin® for a cell-to-tab joints in Li-ion battery packs examining influence of laser-related parameters such as laser speed, laser power, and amplitude on the properties of welds and optimized the parameters by using Taguchi method. Initially aluminum and Hilumin® sheet materials were joined with laser welding. Electrical resistances of the welded samples were measured. Then, lap shear strengths were determined using the universal tensile device. As a result of the optimizations, it was determined which laser welding parameters would result in the minimal electrical resistance and maximal joint strength. In this study, the preferred minimized electrical resistance and maximized joint strength values for battery interconnection joints, with varying laser power, laser speed, and amplitude parameters, were achieved with a combination of 890 W power, 1 mm amplitude, and 8.5 m/min speed. If optimum parameters are used in establishing the connection, the maximum weld seam strength achieved was 32.36 MPa, and the minimum electrical contact resistance was 0.4186 mΩ. Findings show that laser speed has a significant impact on the formation of the weld, the material structure, strength properties, and the resistance at the electrical contact points. Increasing the laser speed also increased the strength of connection. Laser welding Aluminum Hilumin® Battery interconnections Taguchi analysis Full Text Cite Share Download PDF Status: Under Review Version 1 posted Reviewers agreed at journal 29 Sep, 2025 Reviewers invited by journal 29 Sep, 2025 Editor invited by journal 25 Jul, 2025 Editor assigned by journal 16 Jul, 2025 First submitted to journal 15 Jul, 2025 You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. 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Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-7092430","acceptedTermsAndConditions":true,"allowDirectSubmit":false,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":522076110,"identity":"5db90e99-332b-45a1-a2ee-4b11b8f9a87d","order_by":0,"name":"Aygen Ahsen Yıldırım","email":"","orcid":"","institution":"Rimac Technology","correspondingAuthor":false,"prefix":"","firstName":"Aygen","middleName":"Ahsen","lastName":"Yıldırım","suffix":""},{"id":522076111,"identity":"0c1b4e7a-37a0-4d1d-a03e-c8d9e964cc38","order_by":1,"name":"EROL 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