In battery manufacturing, foils are attached via ultrasonic metal welding, an effective method with some significant drawbacks. These include debris generation, fatigue and cracking, and difficulty with in-process monitoring.
EWI has recently been working with an alternative joining technique for battery foils, capacitive discharge (CD) welding. Its advantages include rapid thermal cycling results, highly localized joint heating, applicability to highly conductive materials, and the ability to join many layers of foil with a single weld.
EWI associates Kate Namola, Tim Frech, and Jerry Gould have written Joining of Copper Foils by Capacitive Discharge Welding which discussed EWI’s research on this topic. To download this paper, please complete the form on this page.