Скачать или смотреть Defeating Oxidation & Warping: The CCS Aluminum-Nickel Welding Breakthrough

Video Description

In the precise world of battery module and power electronics assembly, joining dissimilar metals like aluminum and nickel for Cell Connection Systems (CCS) presents a dual challenge: preventing interfacial oxidation during welding and avoiding part distortion during downstream stamping.

This is the proven solution. Our Polymer Diffusion Welding process integrates two key innovations to deliver flawless results: 1) Custom Welding Gaskets that create a localized protective atmosphere to eliminate oxidation at the joint, and 2) A "Weld-First, Stamp-After" sequence that guarantees zero edge warping. Witness how we achieve robust, reliable Al-Ni bonds ready for precise secondary forming.

🔬 The Engineering Strategy: Solving Dual-Process Challenges

Gasket-Enabled Oxidation Prevention: A specially designed gasket surrounds the weld area during the solid-state diffusion cycle. This physically bars ambient air and can be purged with an inert gas if needed, ensuring the pristine, oxide-free aluminum and nickel surfaces bond directly at an atomic level. This is critical for achieving low and stable electrical contact resistance.

Sequential Process Integrity: By performing the solid-state diffusion weld first, we create a stable, metallurgically unified component. This bonded assembly has relieved the internal stresses induced by welding. Subsequent stamping or punching operations then act on this stable base, eliminating the warping or cracking that occurs if stamping (which work-hardens and stresses the material) is done before welding.

✅ Tangible Production Benefits for CCS & Power Interconnects:
✔ Consistent Electrical Performance: Oxide-free interfaces ensure predictable, low-resistance connections critical for battery pack efficiency and safety.
✔ Preserved Part Geometry: No post-weld warping means components fit perfectly into automated assembly lines and final enclosures, reducing rejection rates.
✔ Streamlined Workflow: Enables a logical, efficient production flow (weld → stamp) instead of a corrective one (stamp → warp → try to weld → potentially worsen distortion).
✔ Material Flexibility: This method is highly effective for thin, multi-layered, or clad materials common in modern electrical interconnects.

🏭 Target Applications:

Electric Vehicle Battery Modules: CCS (Cell Connection System) busbars, sensing leads, and module-to-module links.

Energy Storage System (ESS) Busbars: High-current aluminum-nickel interconnects.

Power Electronics: Inverter and DC-DC converter internal busing.

Consumer Electronics Battery Packs: For power tools, laptops, and devices.

📞 Ready to Optimize Your Al-Ni Joining and Stamping Process?
Contact our application engineers to discuss how this integrated welding and forming strategy can be implemented for your specific CCS or busbar components.

➡️ 🌐 Discover More Joining Solutions for Electrification:
www.busbarwelder.com
➡️ 📧 Request the Technical Bulletin: "Best Practices for Welding and Post-Forming Aluminum-Nickel Interconnects":
[email protected]
➡️ 📱 WhatsApp for Process Consultation:
+86 18129519717

#CCSWelding #AluminumNickelWelding #PolymerDiffusion #BatteryManufacturing #NoWarping
#WeldingGasket #OxidationPrevention #EVBattery #CellConnectionSystem #PrecisionStamping
#SolidStateWelding #ProcessIntegration #PowerInterconnects #ManufacturingSolution
#HaifeiWelder #BatteryPack #Engineering #Reliability #ProductionEfficiency