Sealing performance and joining mechanism of magnetic pulse welded joints on 3003 AI prismatic cell container for battery applications

Due to the shape of the prismatic cell container (PCC) and the physical properties of aluminum (Al) alloys, there are limitations in fabrication with common welding methods. Magnetic pulse welding (MPW) is a promising solid-state joining process that provides fast and strong welds without heat-affected zone. Despite the growing interest in this process, there is little understanding of the sealing performance and joining mechanism of PCC structures fabricated by MPW, which is critical for prismatic cell safety. In this study, MPW was used to join the cell case (CCE) and cell cap (CCP) for the fabrication of Al3003 PCC. The sealing performance, mechanical properties and joining mechanism of MPW joints were investigated. The results showed that the overall sealing of the PCC was realized by MPW technology, and the sealing performance reached 0.8 MPa. Peeling tests showed that the strength of the MPW welds was higher than that of the parent material, and one of the main reasons for the excellent strength of the welds was the waveform interface formation. Furthermore, the appropriate collision speed and angle were the key factors for welds generation, which ranged from 315 m/s to 360 m/s and 2–10°, respectively. This study provides potential options for the fabrication of Al PCC for electric vehicles.