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Robotic friction stir welding in lightweight battery assembly of extrusion-cast aluminium alloys
University West, Department of Engineering Science, Division of Welding Technology. (KAMPT)ORCID iD: 0000-0002-9015-7372
University West, Department of Engineering Science. (KAMPT)
University West, Department of Engineering Science, Division of Welding Technology. (KAMPT)ORCID iD: 0000-0002-6820-4312
University West, Department of Engineering Science, Division of Production Systems. Friction & Forge Processes, TWI, Cambridge (GBR). (KAMPT)ORCID iD: 0000-0001-9553-7131
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2023 (English)In: Journal of Advanced Joining Processes, ISSN 2666-3309, Vol. 8, article id 100156Article in journal (Refereed) Published
Abstract [en]

The present study focuses on developing lightweight assembly of two different aluminium alloys extruded and high pressure die cast (HPDC) for battery frame assembly in BEV. The goal is to produce defect-free welds in lap configuration with smooth surface finish. Stationary shoulder friction stir welding (SSFSW) was employed with welding speeds of 3–15 mm/s. EBSD analysis revealed two groups of grains in the stir zone (SZ) due to dynamic recrystallization. Moreover, the grain size of the SZ significantly decreased compared to both alloys. The cast alloy contains large iron particles, and that were broken by the rotating probe, and the stirred material consisted of fine dispersed precipitates. Tensile-shear test found the fracture location at the hook area near to cast, and a model representing fracture behavior is also discussed. With increasing welding speed from 3 to 5 mm/s, the tensile strength found ∼95 and ∼100 MPa, respectively without any significance difference in the fracture behavior and location. Overall, this study provides valuable insights such as materials mixing, grain refinement, and joint strength in dissimilar joining using SSFSW. The findings could be useful in developing optimized welding parameters and improving the overall quality and productivity of the SSFSW process for battery pack assembly in BEV.

Place, publisher, year, edition, pages
2023. Vol. 8, article id 100156
Keywords [en]
Stationary shoulder friction stir weldingAluminium alloysHPDCExtrusionLightweightBEV
National Category
Manufacturing, Surface and Joining Technology
Research subject
Production Technology
Identifiers
URN: urn:nbn:se:hv:diva-21003DOI: 10.1016/j.jajp.2023.100156ISI: 001085211200001Scopus ID: 2-s2.0-85172304340OAI: oai:DiVA.org:hv-21003DiVA, id: diva2:1814490
Note

The funding support from the VINNOVA project of EVASTIR (2019-03114) with industry partners Volvo Cars Corporations, Hydro Extruded Solutions, ESAB, and i-Weld project H2020-MSCA-RISE-2018 (Project number: 823786) are highly acknowledged.

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Available from: 2023-11-24 Created: 2023-11-24 Last updated: 2024-04-03Bibliographically approved

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Patel, VivekBaghdadchi, AmirDe Backer, JeroenIgestrand, MattiasAndersson, Joel

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