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Ultrasonic Metal Welding for Lithium-Ion Battery Cells

A standard electric vehicle (EV) automotive battery can be decomposed into cell level, module level, and pack level. A cell mainly includes the anodes and cathodes, a module includes multiple cells, and a pack includes multiple modules. The three most common metal-to-metal joints in a lithium-ion battery pack are foil-to-tab, tab-to-tab, and tab-to-bus. All three […]

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The Battery Show 2021

The Battery Show and EV Technology Expo September 14-16, 2021 Suburban Collection Showplace, Novi, Michigan EWI Senior Engineer Tim Frech will present “Pulsed Arc Welding of Battery Tabs and Cell Interconnections” at the Battery Show on September 14th, 3:00-3:45 pm EDT.

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New Capacitive Discharge Welding Process Enables In-process Monitoring for Battery Pack Joining

While ultrasonic and laser welding are both effective methods for battery foil welding, neither can be monitored in process. So when a battery batch is defective, the problem is not identified until after material, time, and money as been spent. EWI recently tested a resistance spot welding technique that uses a capacitive discharge power supply […]

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Better Joining Technology for Lithium Battery Packs

The integrity and reliability of joints in lithium-ion battery packs is critically important to manufacturers in industries ranging from automotive to consumer electronics to aerospace. If battery packs fail, it can result in more than just a faulty product — it can actually be a threat to public safety. Many welding techniques are used to […]

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Knurl Design Optimization for Foil-to-Tab Welding in Lithium-ion Battery Cells

EWI has developed a novel ultrasonic metal welding (UMW) knurl design which significantly improves the quality of foil-to-tab joints in lithium-ion battery cells. The new design allows multiple-layers to be joined in a single operation without pre-consolidation of the foils and without the use of buffer material or thicker sandwich foils. Download this paper for […]

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Free Technical Webinar: Ultrasonic Metal Welding Foils to Tabs for Lithium Ion Battery Cells on March 22nd

EWI is offering another free technical webinar on Tuesday, March 22 at 2pm EST. Mitch Matheny will present “Ultrasonic Metal Welding Foils to Tabs for Lithium Ion Battery Cells.” Click here now to sign up. Registration is open to the public. The one-hour webinar will review recent advances in tool design for ultrasonic metal welding of multi-layer foil […]

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2012 Battery Symposium | May 2-3 | Columbus, OH

EWI, OSUCAR, and CAR Technologies are hosting the 2012 Battery Symposium May 2-3 in Columbus, OH.  We have a great line up of key note speakers including Tien Duong from the US Department of Energy, as well as industry leaders from Ford and IHS Automotive. This two day event is great for designers and manufacturers, and […]

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Press Release: 2012 Battery Symposium: Life, Reliability& Manufacturing

April 18, 2012 (Columbus, Ohio) – EWI and the Ohio State Center for Automotive Research (CAR) are hosting the 2012 Battery Symposium: Life, Reliability and Manufacturing on May 2-3, 2012 in Columbus. It is the third time the organizations have joined forces to share battery technology knowledge and innovation with industry in a 2-day, convention-style […]

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May 2-3: 2012 Battery Symposium: Life, Reliability & Manufacturing

Don’t miss the 2012 Battery Symposium on May 2-3 in Columbus!  There’s still time to register if you hurry. This is the third time that EWI and the Ohio State Center for Automotive Research (CAR) have joined forces to bring you a 2-day Battery Symposium packed with technology presentations, discussions, exhibits, networking, free food, and more. Our last […]

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Harnessing the Power of FEA: Hydrogen Diffusion Challenges in Pipelines

Harnessing the Power of Finite Element Analysis Part 5: Hydrogen Diffusion Challenges in Pipelines By Amin Moghaddas Finite Element Analysis (FEA) has emerged as a critical tool for mass diffusion analysis across various industries. By simulating the movement of particles, such as gases or liquids, through materials under different conditions, FEA enables engineers to predict […]

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