R. PALANIVEL: A CONTEMPORARY REVIEW OF THE ADVANCEMENTS IN JOINING TECHNOLOGIES ...
275–281
A CONTEMPORARY REVIEW OF THE ADVANCEMENTS IN
JOINING TECHNOLOGIES FOR BATTERY APPLICATIONS
SODOBEN LITERATURNI PREGLED UPORABE NAPREDNIH
POSTOPKOV SPAJANJA ZA IZDELAVO BATERIJ
Ramaswamy Palanivel
Shaqra University, College of Engineering, Department of Mechanical Engineering, Dawadmi, Riyadh 11911, Saudi Arabia.
Prejem rokopisa – received: 2023-02-16; sprejem za objavo – accepted for publication: 2023-04-21
doi:10.17222/mit.2023.797
The joining of multilayered foils to a conductive tab necessitates a joining process in the battery, which is an important storage
device in renewable-energy sectors. Cell, module, and pack are the three levels of pouch cell joining in a battery pack. The join-
ing of multi-layered dissimilar conductive materials is necessary for battery-pack fabrication. Mostly copper (Cu) and alu-
minium (Al) are used in battery-pack applications. The Cu and Al are characterized as high thermally and electrically conduc-
tive materials. However, obtaining a quality Cu-Al weld using conventional methods is hard and the durability of the weldments
is uncertain. In general, the development of intermetallic compounds (IMCs) during welding is a major challenge for the joining
of dissimilar materials due to the differences in the chemical and physical properties. This review addresses the battery packs
and challenges involved in joining the conductive tabs. In addition, this review provides an insight into the suitability of various
joining processes and explores their suitability for the joining of battery packs.
Keywords: friction-melt bonding, renewable energy storage, Li-ion battery, welding; joining, friction-stir spot welding, resis-
tance welding, laser-beam welding, ultrasonic welding
Spajanje ve~plastnih folij na prevodne plo{~ice je nujen postopek pri izdelavi baterij, ki so pomembne naprave za shranjevanje
elektri~ne energije na podro~ju obnovljive energije. Celica, modul in paket so tri ravni baterijskega sklopa, shranjeni v enovito
celoto. Medsebojno spajanje ve~ plasti materialov z razli~no prevodnostjo je nujno za uspe{no izdelavo baterijskega sklopa.
V glavnem se uporabljata za baterijske sklope dva materiala: baker (Cu) in aluminij (Al). Oba materiala imata odli~no toplotno
in elektri~no prevodnost vendar je za izdelavo kakovostnega Cu-Al zvara uporaba konvencionalnih postopkov te`avna in trajnost
zvarov slaba oz. nezanesljiva. V glavnem je pri tem problem nastajanje intermetalnih spojin zaradi razlik v kemijskih in
fizikalnih lastnosti. Avtorji opisujejo glavne izzive in probleme s katerimi se sre~ujejo izdelovalci baterijskih sklopov zaradi
spajanja prevodnih priklju~kov. Poleg tega pregled literature ponuja vpogled o primernosti uporabe razli~nih postopkov
spajanja baterijskih sklopov.
Klju~ne besede: spajanje v talini s pomo~jo trenja, shranjevanje obnovljive energije, litij-ionske baterije; varjenje, spajanje,
to~kovno varjenje s pomo~jo trenja med vrtenjem obremenjenega trna, uporovno varjenje, lasersko varjenje, ultrazvo~no
varjenje
1 INTRODUCTION TO Li-ION BATTERY PACKS
AND JOINTS
The production of electricity through renewable en-
ergy is a global demand. On the other hand, the require-
ment of energy storage is essential. Rechargeable storage
devices are the key players in storing the produced re-
newable energy. Most storage devices are made from
lithium (Li) ion batteries for renewable and portable en-
ergy needs. The packing efficiency of the pouch cell bat-
tery packs are the highest among the categories in Li-ion
batteries. These batteries are categorized as prismatic,
cylindrical and pouch cells.
1
Conductive foil tabs that are
attached to the electrodes are used to position the cylin-
drical pouch cells. The pouch-cell arrangement contains
levels like pack, module and cell. The level of cell con-
figuration contains Li cathode and graphite anode foils
that are filled with electrolytes. The Li foil is positioned
over aluminum (Al) and copper (Cu) collectors that are
joined to the tab. At the module level, the cells are joined
and at the pack level, modules are joined.
2
The configu-
ration and characteristics of Li-ion battery packs are pre-
sented in Table 1. The above-mentioned joints require
the welding of multi-layered Cu and Al for battery
packs, as mentioned in Figure 1. Considering the cost
effectiveness and quality of the weld, the automated
welding methods are preferred for battery packs. As in
the case of mechanical joining, it provides better strength
and ease of disassembly; however, it increases the weight
of the battery pack and these joints are susceptible to
corrosion. Joint preparation using resistance welding
(RW) produces quality weldments. Besides, employing
RW over conductive materials like Cu and Al needs a
high electric current and more time to prepare the joints.
This leads to an excessive heat input, causing intrinsic,
localized fusion and creates extensive deformation.
3
La-
ser beam welding (LBW) involves a low heat input but
causes melting of more materials to be joined, which
may lead to cracks, due to solidification and the develop-
ment of undesirable intermetallic compounds while dis-
Materiali in tehnologije / Materials and technology 57 (2023) 3, 275–281 275
UDK 621.792.3:621.352.1 ISSN 1580-2949
Original scientific article/Izvirni znanstveni ~lanek MTAEC9, 57(3)275(2023)
*Corresponding author's e-mail:
rpalanivelme@gmail.com (Ramaswamy Palanivel)

similar joining.
4
Friction-melt bonding (FMB) is one of
the alternatives to the multi-layered welding of Cu and
Al in battery packs. FMB is a variant of the friction-stir
spot welding (FSSW) process that produces a spot – lap
welding. FMB uses a non-consumable tool that produces
the joints by plasticizing the region with frictional heat
because of the forging pressure. FMB involves stages
like initial rotation, plunging and retracting. The joints
produced have excellent mechanical properties with very
thin intermetallic layers.
5,6
2 CHALLENGES INVOLVED IN BATTERY PACK
DESIGN
This section deals with the various complexities in-
volved in the fabrication of battery packs, such as the
challenges with respect to mechanical loading, electro-
mechanical, thermal and metallurgical influences are dis-
cussed in a brief note.
2.1 Mechanical aspects
Mechanical phenomena play a crucial part in bat-
tery-module functioning, as well as safety standards. The
modules in a battery are subjected to dynamic loading
and vibrations while in operation. Additionally, the
pre-stressing of the battery interconnection joints be-
cause of the interconnecting by joining may visibly im-
pair the dynamic responsiveness of the complete battery
back.
7
When being charged and discharged, lithium-ion
batteries typically exhibit dynamic behaviour in the
structure. This effect may last forever, attributed to the
irreversible expansion of the electrodes and pressure dif-
ference in the cell.
8
It is essential to take electromechani-
cal effects into account since the mechanical connections
between batteries and conductors serve both structural
and electrical purposes by transferring current to or from
the cells. In structural applications, fatigue is a
well-known issue that can be troublesome, however it
can also lead to an increase in electrical resistance. The
fatigue life is predicted using the impedance of speci-
mens throughout the fatigue tests, where the interaction
between impedance and fatigue failure is separated from
one of the factors, such aas variation in the length of the
specimen.
9
Thermal aspects: materials with different
thermal expansions at the joint interface produce heat
that cause inhomogeneous thermal expansion. This leads
to shear loading and may cause fracture in the prepared
joint. This shear loading ultimately affects the contact in-
terface and connection resistance.
10
2.2 Metallurgical aspects
It is well known that joints that are available in elec-
tric contacts and integrated circuits experience corrosion,
the degradation of material qualities and functionality.
R. PALANIVEL: A CONTEMPORARY REVIEW OF THE ADVANCEMENTS IN JOINING TECHNOLOGIES ...
276 Materiali in tehnologije / Materials and technology 57 (2023) 3, 275–281
Figure 1: Configuration of cell level battery welded to anode tab (Re-
drawn from reference
30
)
Table 1: Configuration of Li-ion cell structure and type of joining methods employed in battery packs
Li-ion cell structure
Li-ion configuration
Characteristics Type of joint
Cell Pack
Cylindrical type
Packing density: Poor
Individual cell capacity:
Poor
Cost: Low
Casing: Hard
Wire bonding
Mechanical fastening
Prismatic type
Packing density: High
Individual cell capacity:
High
Cost: Expensive
Casing: Hard
Mostly Mechanical fas-
tening
Laser welding
Resistance welding
Pouch type
Packing density: High
Individual cell capacity:
High
Cost: Inexpensive
Casing: Soft
Ultrasonic welding
Mechanical fastening

Here, atmospheric, localised, pitting, and galvanic corro-
sion are the most well-known and obvious forms.
In-depth research into fretting in microelectronics and
electronic connections revealed that it can be seen in
practically all regularly used conductor materials, such
as copper, aluminium, or nickel, and that it has a notice-
able impact on connection resistance.
10
In mechanically
linked electrical connections, metal-to-metal contacts are
where the more significant process of degradation takes
place. Direct effects of intermetallic compounds, such as
those between copper and aluminium, include a reduc-
tion in mechanical strength and an increase in electrical
connection resistance. During joining, the formation is
both conceivable and frequently controllable. Further-
more, power and temperature during operation can pro-
mote diffusion and hence enable uninhibited creation.
11
3 ESSENTIAL CRITERIONS FOR
BATTERY-PACK JOINING
To analyse the possibility of joining the interconnec-
tions of the battery, interdisciplinary requirements must
be investigated. The four major categories to be consid-
ered as per Das et al.,
12
for the battery-pack joining are
shown in Table 2.
Table 2: Essential criteria to be considered for battery-pack joining
Major category Essential criterions
Mechanical aspects
-Interconnection to be intact
-Vibrational damage to be
avoided during joining
-Better fatigue life
Thermal aspects
-Low electrical resistance at
joint interface
-Creep resistance
Metallurgical aspects
-Less corrosive
-Ability to join dissimilar
materials
Economic aspects
-Durability
-Easy to produce in bulk
4 PROBLEMS ASSOCIATED WITH VARIOUS
BATTERY-PACK JOINING TECHNOLOGIES
The various problems with respect to battery-pack
joining methods are discussed below and the challenges
as well as the benefits with respect to battery-pack join-
ing technologies are depicted in Table 3.
4.1 Mechanical fastening (MF)
Mechanical joining can be divided into two groups:
integral joints and fasteners. Nuts, bolts, screws are all
types of fasteners. Seams, snap-fits, are examples of inte-
gral joints. Therefore, the primary benefit of mechanical
connecting is its simplicity in disassembling for upkeep
and repair. Additionally, mechanical joining is often
done without heat, with the possible exception of a few
unique circumstances. However, additional mass to cell
pack, corrosion issues and intensive labour are the key
challenges of mechanical fastening.
13
4.2 Resistance welding (RW)
The localized heating and fusion at the joint interface
is obtained by the electrical resistance. Resistance weld-
ing is a faster process, and it can be easily automated. On
dealing with battery-pack joints, employing resistance
welding is challenging because of its non-suitability for
highly conductive materials. Moreover, dissimilar metals
are difficult to join. In the case of battery joints, large
weld nuggets are essential, which is also difficult in re-
sistance welding.
14
In the case of the resistance welding
of dissimilar alloys, the formation of a thin intermetallic
layer must be taken into consideration. However, the
intermetallic layer’s formation can be restricted by con-
trolling the heat input.
4.3 Projection welding (PW)
It is a type of spot welding that provides a good joint
for battery tabs. The projection joints increase the cur-
rent density, which causes heat generation. Also, the
welding of thicker slabs is possible, whereas, weldability
is poor for highly conductive multi-layered materials and
dissimilar materials.
14
4.4 Laser-beam welding (LBW)
It is a non-contact joining process, which is capable
of joining multiple pieces of materials. The weld is cre-
ated as the material is rapidly heated by the powerful la-
ser beam, usually in milliseconds. Laser welding has
been used widely for joining battery packs, owing to its
various benefits, such as a high speed, precise welding
process that produces less distortion. Laser welding is
challenging in materials like Cu and Al due to high re-
flectivity and thermal conductivity. Most often a poor
metallurgical bond between Cu and Al limits this laser
welding, as it produces weld defects like intermetallic
brittle phases.
15,16
4.5 Ultrasonic welding (UW)
In the process of ultrasonic metal welding, a high-fre-
quency ultrasonic energy is utilised to form solid-state
connections by generating oscillating shears between
two sheets that are pressed together. The primary benefit
of ultrasonic welding is suitable for dissimilar materials,
and it is capable of joining stacks of multiple thin sheets
and foils. As the working temperature of this welding is
low and even if it provides sound welding on materials
like Cu and Al. The drawback of ultrasonic welding is
that this process is only suitable for thin sheets, and it is
sensitive to surface conditions. It is also difficult to join
high-strength materials using the method.
17
R. PALANIVEL: A CONTEMPORARY REVIEW OF THE ADVANCEMENTS IN JOINING TECHNOLOGIES ...
Materiali in tehnologije / Materials and technology 57 (2023) 3, 275–281 277

5 EMERGING JOINING METHODS FOR
BATTERY CONDUCTIVE TABS
The alternative joining methods used for battery ap-
plications are joining by forming technologies and fric-
tion-assisted welding processes.
5.1 Joining by forming technologies
This process involves plastic deformation of at least
one of the combining materials. Impact welding, roll
bonding are some of the solid-state methods involved in
joining by forming technologies. Recently, Pragana et
al.
19
fabricated Cu-Al by partial cutting and bending with
a compression form-fit process. This technology enables
the joining of dissimilar materials, irrespective of their
high conductivity. Moreover, the problem associated
with these forming technologies are the difficulty of
joining more than two or three layers of sheet metal and
thr accessibility of the parts is difficult.
5.2 Friction-based joining processes
It is a solid-state method being adopted to join bat-
tery tabs using frictional heat. The main advantage of
this process is dissimilar materials like Cu and Al can be
joined without the formation of brittle intermetallic lay-
ers. Mypati et al.,
20
welded a Cu-Al cell tab successfully.
However, the left out exit hole is the major drawback of
this process. The various friction-based joining processes
that are found to be suitable for battery-tab joining pro-
cesses are friction-assisted joining, friction spot joining,
friction riveting, friction lap welding
20–24
5.3 Friction melt bonding
FMB is a novel joining technology that takes advan-
tage of the substantial temperature variations between
the materials to be bonded. Figure 2 shows a diagram of
this process. One plate is placed on top of the other and
fixed together in FMB. The top surface of the plate is
forced against a rotating flat cylindrical tool, which gen-
erates heat through friction and creates a deformation.
The frictional heat generated raises the temperature of
the top plate to near the melting point of the bottom
plate. As a result, both the top and bottom plates melt
and react locally, forming an intermetallic layer. The tool
moves on the surface of the top plate to form a continu-
ous weld seam with prolific weld quality and with mini-
mal welding defects.
25–28
5.4 Refill friction-stir spot welding (RFSSW)
RFSSW is one of the solid-state techniques used for
joining thin layers in batteries. It forms a spot weld with-
out melting the materials, with better quality of the weld.
This technique has a tool with a probe, adjustable shoul-
der and clamp ring, as shown Figure 3. RFSSW is one
R. PALANIVEL: A CONTEMPORARY REVIEW OF THE ADVANCEMENTS IN JOINING TECHNOLOGIES ...
278 Materiali in tehnologije / Materials and technology 57 (2023) 3, 275–281
Table 3: Challenges involved in battery pack joint technologies
S. No.
Type of joining technology
in battery application
Benefits Challenges
1 Mechanical fastening
13
-Higher joint strength
-Easier assembly/disassembly
-No requirement for heat source
-Additional mass to cell pack
-Corrosion issues
-Work intensive
2 Resistance welding
13
-Faster process
-Easy to automate
-Not suitable for highly conductive materi-
als
-Difficult to weld dissimilar materials
-Large weld nuggets are not possible, as it
is essential for battery packs. Large welds
help to reduce electrical resistance
3. Projection welding
10
-Welding of thicker slabs are possible
-Poor weldability for highly conductive dis-
similar materials
4. Laser-beam welding
15,16
-Less distortion
-Highly precise process
-High speed, non-contact process
-Producing large joint area is difficult
-Material reflectivity
-Necessity for shielding gas
5. Ultrasonic welding
18
-Suitable for conductive materials and thin
sheet metals
-Dissimilar materials can be joined
-Solid-state process
-Restricted to lap joints
-Sticking of sonotrode (electrode)
-Sensitive to surface conditions
Figure 2: Schematic setup of friction melt bonding

of the solid-state welding techniques that evolved from
friction-stir welding. Tool traverse on the materials to be
welded is not associated in this process. So, it forms a
spot weld without melting the materials with better qual-
ity on the weld properties. This technique has a rotating
probe, adjustable shoulder and clamp ring, as shown Fig-
ure 3. RFSSW takes place in four stages: 1) the tool
moves to the top surface of the plate and rotation starts to
generate frictional heat to make the materials sufficiently
soft. 2) Shoulder is plunged to the top plate to retract the
materials to form a gap through which flow of the dis-
placed material takes place. 3) Rotating tool is used to
return retracted the material to the top surface, leading to
consolidation of the weld and the welding process is fin-
ished
29-30
6 NECESSITY FOR AN ALTERNATIVE JOINING
TECHNOLOGY
Batteries made of Li-ion are used in most renew-
able-energy storage devices, and the cells are categorised
as pouch, prismatic, or cylindrical.
1
The pouch cell has
the highest packaging efficiency (95%) compared with
battery packs. Its great efficiency is due to its design,
which uses conductive foil-tabs soldered to electrodes in-
stead of metallic cylinders and a glass-to-metal electric
feed through.
2
Figure 1 depicts the procedure of combin-
ing a battery pack with a pouch cell design. As a result,
the connecting of many layers is critical in the fabrica-
tion of batteries. For both financial and quality concerns,
the cell welding process must be highly automated. Al-
though mechanical connecting offers the best strength
and simplicity of disassembly, it also adds more pieces
and mass to the cell, making it more prone to corrosion.
13
To join stacked Cu and Al to a conducting tab in battery
pouches, welding methods are required.
10
However, these
approaches have drawbacks that prevent them from be-
ing widely used in battery manufacturing.
16
7 DISCUSSION ON JOINING TECHNOLOGIES
FOR BATTERY PACKS
MF stands out because it joins simply by imparting
force, which produces little heat. Furthermore, the con-
nection resistance as well as the scatter range were
recorded to be low. However, this method involves addi-
tional parts which increases the weight and manufactur-
ing complexity while also limiting automation. The loos-
ening of connections was recorded. Based on the above
considerations, MF cannot be a suitable method for man-
ufacturing battery packs. RW is a low-cost process that
has been used in industry. However, stabilising the pro-
cess is challenging due to various influencing parame-
ters. Moreover, if the process is regulated for a particular
welding operation, preserving quality is possible. As a
result, it is suitable for a regulated welding activity with
a lot of cycles, like making battery modules. Resistance
spot welding is also a good choice for either type of weld
task because it naturally has the benefit of welding lo-
cally at the joining surfaces. LBW produces a low con-
densation resistance, low scattering, and produces excel-
lent weld strength. Furthermore, the heat input was the
lowest among all the presented process technologies.
This offered the possibility to extend LBW as an auto-
mated method. However, LBW is a costlier process due
to the requirement for a shielding gas, tool and alignment
of joints. A high-quality weld depends on the chosen
processing window. In joining the interconnector to the
cell, it is essential that LBW must completely melt
throughout the interconnector. In the case of large pris-
matic cells, LBW must be employed to weld a large vol-
ume of material. For battery-pack joining applications,
the LBW and RW are suitable. On considering the eco-
nomic aspects, less environmental impact and process
stability RW technology is convenient. Ultra-sonic weld-
ing is a solid-state process supported with self-tool and it
is well suited for joining conductive metals. Moreover,
heat generation during the process was found to be infe-
rior, particularly for battery-pack joining. Additionally,
connection resistance is high when compared to welding
techniques. As a result, UW may be regarded as unsuit-
able for cylindrical battery cell welding, but suitable for
pouch and cylindrical cell interconnection. Welding us-
ing forming technique is practically not suitable for con-
necting cylindrical cells due to the penetration takes
place in the battery cell. However, it can be used to con-
nect the pouch cell and prismatic when the tabs are lo-
cated externally in the former case. Interconnection
R. PALANIVEL: A CONTEMPORARY REVIEW OF THE ADVANCEMENTS IN JOINING TECHNOLOGIES ...
Materiali in tehnologije / Materials and technology 57 (2023) 3, 275–281 279
Figure 3: Schematic representation of process sequence involved in Refill friction stir spot welding (Redrawn from reference
30
)

busbars are an alternative for this method. Softening of
aluminium is the major challenge that leads to the issues
and should be investigated thoroughly for the particular
application. Therefore, welding using forming technolo-
gies seems to be a workable strategy provided that the
joining partners are reachable and that application-re-
lated difficulties are resolved. Friction based welding has
not been widely used in battery interconnections. How-
ever, it appears to be advantageous from a metallurgical
standpoint, as the formation of an intermetallic is un-
avoidable, particularly in dissimilar material combina-
tions. Friction-based welding produces less heat than fu-
sion welding. However, it has not been investigated
whether frictional heat can damage battery cells. It is un-
clear whether welding can cause thermal or physical
damage to the cells. Clamping the joining partners can
be difficult if the battery-connector joint designs become
difficult. Some of the benefits of utilizing friction-based
joining processes are shorter joining time, energy effi-
cient, better joint strength, shorter installation time and
suitable for dissimilar joints. At this point, it is possible
to conclude that the technology has the potential to be
used in battery interconnections, but additional research
is required.
8 CONCLUSION
This review allows for a comprehensive idea about
employing various joining technologies, allowing dura-
ble joints with low connection resistances.
When comparing battery welding-joining technolo-
gies it is clear that adapting to a technology is dependent
not on connection resistance but also depends on the
joining task.
Ultrasonic welding was found to be suitable for join-
ing pouch cells.
Laser welding can be used to join cylindrical cells.
Moreover, it may be less effective for large cells with
geometrically large interconnectors. Also, la aser re-
quires an entire melting of the connector regardless of its
size.
Resistance welding is flexible for all battery-cell
types as the joining happens locally.
Friction-based welding is observed to be beneficial
owing to the shorter joining time, energy efficient, better
joint strength, and suitability for dissimilar materials.
Acknowledgment
The author extends their appreciation to the Deanship
of Scientific Research at Shaqra university, Saudi Arabia
for supporting this work.
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