Automotive Engineering - March 2023 - BET6

Thermal Management
plates required for today's EV battery
systems, which rely on cooling plates
measuring up to 2.1 x 1.3 m.
As demand for larger cooling plates
increases, vacuum brazing inefficiencies
become apparent. Brazing is slow
and consumes a lot of energy (>4 MW),
which leads to high operating cost. A
single production line can take up 800
square meters of production floor space.
The increasing
size of
Figure 1: Providing a mechanical and thermal interface to regulate EV battery temperature.
Cooling plates provide leak-free coolant flow that improves battery performance and extends
battery life. (Image: Civan Lasers)
the
cooling
plates also requires significant capital
investment in larger vacuum furnaces,
which can cost more than 5 million
euro for a single furnace.
Brazing also requires the use of Al
Battery for Hybrid Cars
3003, a special aluminum alloy that can
be brazed. Manufacturers want to
switch to more economical alloys such
as Al 5754, which can be brazed but
requires a postprocessing treatment,
and Al 6xxx series alloys, which have
the advantage of being recyclable but
can't be brazed at all. They are searching
for faster, more efficient joining
methods that will help them keep up
with
increased
demand
and
adoption of new metal alloys.
Laser Welding: A Promising
Solution
Adoption of laser materials processBattery
for Plugin Cars
ing technology accelerates with increased
reliability, robustness, and availability
of multikilowatt lasers. Compared
to the traditional welding processes,
laser welding reduces production costs,
and increases manufacturing flexibility
and selectivity.
Laser welding technology also requires
less heat input, which minimizes distortion
potential while maximizing speed.
All welding methods involve melt-pool
formation and subsequent rapid solidification.
However, the high energy of laser
welding not only melts material but also
evaporates it.1
Evaporation of material during the
Battery for Electric Vechicles
Figure 2: The size of the cooling plates has increased with each EV evolution - hybrid electric
vehicle (HEV) to plug-in HEV to full EV. (Image: Civan Lasers)
6
welding process creates a keyhole, which
gives laser welding the advantage of a
very ratio of penetration depth to weld
seam width (Figure 3). Consequently,
many manufacturers have switched from
traditional brazing and welding to laser
materials processing, which can join a
variety of materials, reduce power consumption,
and improve process yields.
Battery & Electrification Technology, March 2023
speed

Automotive Engineering - March 2023

Table of Contents for the Digital Edition of Automotive Engineering - March 2023

Automotive Engineering - March 2023 - INTRO1
Automotive Engineering - March 2023 - SPONSOR1
Automotive Engineering - March 2023 - CVR1
Automotive Engineering - March 2023 - CVR2
Automotive Engineering - March 2023 - 1
Automotive Engineering - March 2023 - 2
Automotive Engineering - March 2023 - 3
Automotive Engineering - March 2023 - 3A
Automotive Engineering - March 2023 - 3B
Automotive Engineering - March 2023 - 4
Automotive Engineering - March 2023 - 5
Automotive Engineering - March 2023 - 6
Automotive Engineering - March 2023 - 7
Automotive Engineering - March 2023 - 8
Automotive Engineering - March 2023 - 9
Automotive Engineering - March 2023 - 10
Automotive Engineering - March 2023 - 11
Automotive Engineering - March 2023 - 12
Automotive Engineering - March 2023 - 13
Automotive Engineering - March 2023 - 14
Automotive Engineering - March 2023 - 15
Automotive Engineering - March 2023 - 16
Automotive Engineering - March 2023 - 17
Automotive Engineering - March 2023 - 18
Automotive Engineering - March 2023 - 19
Automotive Engineering - March 2023 - 20
Automotive Engineering - March 2023 - 21
Automotive Engineering - March 2023 - 22
Automotive Engineering - March 2023 - 23
Automotive Engineering - March 2023 - 24
Automotive Engineering - March 2023 - 25
Automotive Engineering - March 2023 - 26
Automotive Engineering - March 2023 - 27
Automotive Engineering - March 2023 - 28
Automotive Engineering - March 2023 - 29
Automotive Engineering - March 2023 - 30
Automotive Engineering - March 2023 - 31
Automotive Engineering - March 2023 - 32
Automotive Engineering - March 2023 - 33
Automotive Engineering - March 2023 - CVR4
Automotive Engineering - March 2023 - BETCVRA
Automotive Engineering - March 2023 - BETCVRB
Automotive Engineering - March 2023 - BETCVR1
Automotive Engineering - March 2023 - BETCVR2
Automotive Engineering - March 2023 - BET1
Automotive Engineering - March 2023 - BET2
Automotive Engineering - March 2023 - BET3
Automotive Engineering - March 2023 - BET4
Automotive Engineering - March 2023 - BET5
Automotive Engineering - March 2023 - BET6
Automotive Engineering - March 2023 - BET7
Automotive Engineering - March 2023 - BET8
Automotive Engineering - March 2023 - BET9
Automotive Engineering - March 2023 - BET10
Automotive Engineering - March 2023 - BET11
Automotive Engineering - March 2023 - BET12
Automotive Engineering - March 2023 - BET13
Automotive Engineering - March 2023 - BET14
Automotive Engineering - March 2023 - BET15
Automotive Engineering - March 2023 - BET16
Automotive Engineering - March 2023 - BET17
Automotive Engineering - March 2023 - BET18
Automotive Engineering - March 2023 - BET19
Automotive Engineering - March 2023 - BET20
Automotive Engineering - March 2023 - BET21
Automotive Engineering - March 2023 - BET22
Automotive Engineering - March 2023 - BET23
Automotive Engineering - March 2023 - BET24
Automotive Engineering - March 2023 - BET25
Automotive Engineering - March 2023 - BET26
Automotive Engineering - March 2023 - BET27
Automotive Engineering - March 2023 - BET28
Automotive Engineering - March 2023 - BET29
Automotive Engineering - March 2023 - BET30
Automotive Engineering - March 2023 - BET31
Automotive Engineering - March 2023 - BET32
Automotive Engineering - March 2023 - BET33
Automotive Engineering - March 2023 - BET34
Automotive Engineering - March 2023 - BETCVR3
Automotive Engineering - March 2023 - BETCVR4
https://www.nxtbook.com/smg/sae/24AE12
https://www.nxtbook.com/smg/sae/24AE10B
https://www.nxtbook.com/smg/sae/24AE10
https://www.nxtbook.com/smg/sae/24AE09B
https://www.nxtbook.com/smg/sae/24AE09
https://www.nxtbook.com/smg/sae/24AE08
https://www.nxtbook.com/smg/sae/24AE06
https://www.nxtbook.com/smg/sae/24AE05
https://www.nxtbook.com/smg/sae/24AE04
https://www.nxtbook.com/smg/sae/24AE03
https://www.nxtbook.com/smg/sae/24AE02
https://www.nxtbook.com/smg/sae/23AE12
https://www.nxtbook.com/smg/sae/23AAVE11
https://www.nxtbook.com/smg/sae/23AE10
https://www.nxtbook.com/smg/sae/23AE09
https://www.nxtbook.com/smg/sae/23AE08
https://www.nxtbook.com/smg/sae/23AAVE07
https://www.nxtbook.com/smg/sae/23AE06
https://www.nxtbook.com/smg/sae/23AE05
https://www.nxtbook.com/smg/sae/23AAVE04
https://www.nxtbook.com/smg/sae/23AE04
https://www.nxtbook.com/smg/sae/23AE03
https://www.nxtbook.com/smg/sae/23AE02
https://www.nxtbook.com/smg/sae/23AAVE01
https://www.nxtbook.com/smg/sae/22AE12
https://www.nxtbook.com/smg/sae/22AVE11
https://www.nxtbook.com/smg/sae/22AE10
https://www.nxtbook.com/smg/sae/22AE09
https://www.nxtbook.com/smg/sae/22AE08
https://www.nxtbook.com/smg/sae/22AVE07
https://www.nxtbook.com/smg/sae/22AE06
https://www.nxtbook.com/smg/sae/22AE05
https://www.nxtbook.com/smg/sae/22AVE04
https://www.nxtbook.com/smg/sae/22AE04
https://www.nxtbook.com/smg/sae/22AE03
https://www.nxtbook.com/smg/sae/22AE02
https://www.nxtbook.com/smg/sae/22AVE01
https://www.nxtbook.com/smg/sae/21AE12
https://www.nxtbook.com/smg/sae/21AVE11
https://www.nxtbook.com/smg/sae/21AE10
https://www.nxtbook.com/smg/sae/21AVE09
https://www.nxtbook.com/smg/sae/21AE09
https://www.nxtbook.com/smg/sae/21AE08
https://www.nxtbook.com/smg/sae/21AVE07
https://www.nxtbook.com/smg/sae/21AE06
https://www.nxtbook.com/smg/sae/21AE05
https://www.nxtbook.com/smg/sae/21AVE05
https://www.nxtbook.com/smg/sae/21AE04
https://www.nxtbook.com/smg/sae/21AE03
https://www.nxtbook.com/smg/sae/21AVE03
https://www.nxtbook.com/smg/sae/21AE02
https://www.nxtbookmedia.com