Laser welding and its implementation in the assembly of battery packs in aviation

Following an overview of conventional bonding techniques used for the assembly of battery packs of modern hybrid vehicles special attention will be paid to laser keyhole welding. The unique challenges of aviatic applications, especially joining large number of batteries in a highly reproducible manner are pinpointed. The effect of contact area on the electrical and mechanical properties of laser welded joints is investigated on a DC01 steel model structure. The results are also discussed in terms of laser scanning speed. In the optimal process parameter range joints exhibiting electrical and mechanical properties appealing for assembling hybrid aircraft battery packs can be produced with high reproducibility.