Electrical performance of laser braze-welded aluminum–copper interconnects

The reported investigation is related to laser beam braze-welding technology for dissimilar aluminum–copper interconnects for Li-ion battery assembly. The correlation between the brittle and high-resistivity intermetallic compounds and the electrical contact resistance showed that a thin intermetallic layer is highly desirable. It was proved that highest shear strength and lowest contact resistance can be achieved within the same parameter set which is of particular interest to battery electrical vehicle applications requiring both high mechanical reliability and electrical performance.A study on the weld seam layout further showed that two parallel weld seams with optimized spacing and overlap design provide lowest contact resistance.