Total value of the project: PLN 1,860,750 (including Lukasiewicz – ITR – PLN 456,250)
Funding value: PLN 1,674,675 (including Lukasiewicz – ITR – PLN 410,625)
Project supported by the President of the Lukasiewicz Center in the form of a targeted grant
Project title: “Research on the development of joining techniques for materials intended for battery pack fasteners.”
Project acronym: CellWeld
Project Objective:
The subject of the project will be the selection and development of technologies for joining battery cells and batteries for modern electric cars. The technologies proposed for development, such as ultrasonic and resistance welding, laser beam welding, electron beam welding, and micro-plasma and TIG welding, will optimize the manufacturing process of Polish batteries. The ultrasonic welding process will be carried out on an ultrasonic welding machine manufactured by Łukasiewicz-ITR’s Sonic Welder series using ultrasonic systems (Sonic Blaster series generators, Sonic Converter ultrasonic converters, Sonic Booster boosters and dedicated ultrasonic sonotrodes). The project will develop five dedicated tools for welding packages with different weld outline shapes. FEA simulations of the mechanical wave distribution in the welded parts will be performed. The laser beam welding process will be carried out on a bench equipped with a TruPulse 103 pulsed laser, allowing classic pulsed beam laser welding to be carried out, and a single-mode laser beam welding bench with a fusion depth measurement system planned for purchase. The electron welding process will be carried out on an electron device model XW150:30/756 designed for welding and surface modification. The plasma welding process will be carried out on a bench equipped with an MSP 51 and an Eu Tronic Gap 3001, and TIG welding will be carried out with an ARISTOTIG IG 160 DC (Kemppi). During the technological trials of welding and welding, the technological parameters of the processes will be recorded. Optimization of joining techniques for materials intended as fasteners of battery packs will also require the development of numerical models of welding and welding processes for selected configurations of joining elements and their verification. The SysWeld and Sorpas environment will be used to build numerical (thermal) models to model the temperature fields. The final result of the task will be complete numerical (thermal) models, allowing to determine the temperature of joined elements depending on the technological conditions of welding and welding processes characteristic of 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 the tasks will be carried out in cooperation by Łukasiewicz – Welding Institute, which has equipment to carry out welding and welding processes, by Łukasiewicz – Tele and Radio Research Institute, which has an ultrasonic welder, and by Łukasiewicz – Non-ferrous Metals Institute Central Laboratory of Batteries and Cells, which has advanced equipment for structural, mechanical testing and testing of physical properties of joints.
All information about the project will be provided:
Marcin Kiełbasiński
tel: (22) 590-73-83
e-mail: marcin.kielbasinski@itr.lukasiewicz.gov.pl
(consortium: Łukasiewicz-IS, Łukasiewicz-IMN, Łukasiewicz-ITR)