Insertable thin film thermocouples for in situ transient temperature monitoring in ultrasonic metal welding of battery tabs

Real-time monitoring and control of temperature in ultrasonic joining of battery tabs and coupons are important for the quality improvement and cost reduction of battery assembly. However, there have always been difficulties in accurate and real-time measurement of temperature by conventional sensors for practical implementation. In this study, an innovative method is developed to provide an enabling technology for the in situ transient temperature monitoring, which could provide reliable feedback signals for potential control of ultrasonic joining processes. Micro thin film thermocouples (TFTCs) were fabricated on thin silicon substrates, which were then inserted in the welding anvil as a permanent feature so that the sensors were always located about 100 μm directly under the welding spot during joining of multilayer Ni-coated Cu thin sheets for battery assembly. Good repeatability was demonstrated while a temperature rise of up to 650 °C was obtained due to the closeness of the sensors to the welding spot. The inserts with thin film sensors remained functional after welding experiments. This method has a great potential for in situ transient temperature monitoring, and thus the control of ultrasonic joining processes to realize a practical smart joining system.