BIULETYN INSTYTUTU SPAWALNICTWA No. 1/2019 53 Marcin Alexy, David van de Wall, Geof Shannon, Mark L. Boyle Batteries need strong connections – are resistance, laser and micro TIG welding the best suited joining technologies? Abstract: Te contacting of battery cells is very essential and technologically challenging step during the battery pack manufacturing. Te goal is to achieve best weld joint without defects to enable high current fows. Tis requires high quality welding and joining process. A number of technologies is already well established respectively is typically used to solve most common applications. All three technologies resistance, laser and micro TIG welding are well suited for integration into production lines that may be either standalone or automat- ed operation. To maintain the required throughput that ofers high quality and yields, it is important to have a clear understanding of which process is best for the particular battery pack size, tab and terminal material, type, and thickness. In addition, the selected process and integration solution should include process monitoring, process data management, and weld quality assessment. Keywords: resistance welding, laser welding, micro TIG welding, battery welding doi: 10.17729/ebis.2019.1/6 Introduction Te world becomes more mobile and compo- nents become smaller and therefore the batter- ies and battery packs have become an integral part of everyday life. Batteries are used for port- able electronic devices, cordless power tools, en- ergy storage, hybrid and EV cars and in many other diferent application felds. Te need for longer lasting batteries and battery packs, which continuously meet the increasing quality and production requirements is increasing. Tere are a number of materials joining requirements for battery manufacturing, depending on the specifc type, size and capacity of the battery. Internal terminal connections, battery can and fll plug sealing, tab to terminal connections, and external electrical connections are a few key examples. Several joining options can be considered for each of these requirements, including re- sistance, ultrasonic, micro TIG and laser weld- ing. Te decision to use one or the other is generally dictated by the specifc type of weld required and production requirements. Ultra- sonic welding is commonly used for the join- ing of the internal electrode battery materials, which are usually constructed of thin foils of aluminum and copper. Te remaining join- ing requirements – including the connections inside the can, and external terminal tab con- nections – are well suited to resistance, mi- cro TIG, and laser welding. For can and plug Marcin Alexy, PhD, David Van de Wall – Amada Miyachi Europe; Geof Shannon, PhD, Mark L. Boyle, PhD – Amada Miyachi America