{"id":577,"date":"2024-05-06T13:12:09","date_gmt":"2024-05-06T11:12:09","guid":{"rendered":"https:\/\/www.airenergy.de\/en\/?page_id=577"},"modified":"2024-06-12T15:23:28","modified_gmt":"2024-06-12T13:23:28","slug":"copper-welding-on-cylindrical-cells","status":"publish","type":"page","link":"https:\/\/www.airenergy.de\/en\/leistungen\/copper-welding-on-cylindrical-cells\/","title":{"rendered":"Copper welding on cylindrical cells"},"content":{"rendered":"

Welding copper onto cylindrical cells<\/h3>\t\t\t

Copper is an excellent connector material for round cells when a low-resistance connection is required.<\/span><\/span> Due to the extremely high electrical conductivity of the copper material, a lower voltage drop occurs at high currents.<\/span><\/span> The heating resulting from line losses is also lower.<\/span><\/span> Heat loss from the cells is better dissipated into the environment through the copper.<\/span><\/span> For applications in which high maximum currents occur that fully exploit the performance spectrum of the cells, copper welding is essential.<\/span><\/span><\/span><\/p>\n<\/div>\n\t\t<\/div><\/div><\/div>

Copper welding on round cells 18650<\/h3>

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We will weld for you<\/h3>\t\t\t

Air Energy offers welding of copper connectors on cylindrical cells as a service.<\/span><\/span> Contact us<\/a> to select the right connection technology for your application together with our employees.<\/span><\/span><\/span><\/p>\n<\/div>\n\t\t<\/div><\/div><\/div>

Common welding processes<\/h3>\t\t\t

The most common welding process for round cells such as 18650 or 26650 is resistance welding or spot welding.<\/span><\/span> With this principle, the material melts due to a high current flow through the connector and battery cell.<\/span><\/span> With nickel-plated steel connectors (Hilumin) with a specific conductivity of around 7 S\/m, the current flow creates sufficient heat for a reliable welded connection.<\/span><\/span> However, welding copper with a conductivity of up to 58 S\/m is not reliable using this process.<\/span><\/span> The heat input into the cell is significantly higher and the electrodes become heavily contaminated, even causing the electrodes to stick to the connectors.<\/span><\/span><\/span><\/p>\n<\/div>\n\t\t<\/div><\/div><\/div>

TIG-welding<\/h3>\t\t\t

Air Energy relies on tungsten inert gas welding (TIG) for copper welding of round cells.<\/span><\/span> In this process, the heat required for the melt is created in an arc over the weld.<\/span><\/span> As with resistance welding, highly dynamic control of the arc current allows the power input to be precisely regulated over the course of the weld.<\/span><\/span><\/span><\/p>\n<\/div>\n\t\t<\/div><\/div><\/div>

TIG-welding on cylindrical cells<\/h3>

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Welding systems in use<\/h3>\t\t\t

There are two different technologies available for TIG welding that differ in the way the arc is ignited: Liftarc ignition and HF ignition.<\/span><\/span> For initial sample creation and small quantities, we use a system with Liftarc ignition on an XY table with a travel distance of up to 500mm x 800mm.<\/span><\/span> We weld series projects and larger packs up to 1500mm x 1500mm on a system with HF ignition.<\/span><\/span> Significantly shorter process times compensate for the slightly higher setup effort compared to the system with Liftarc ignition.<\/span><\/span><\/span><\/p>\n<\/div>\n\t\t<\/div><\/div><\/div>

Areas of application<\/h3>\t\t\t

TIG-welded copper connectors on round cells are used at Air Energy in projects that require discharge rates of >1C.<\/span><\/span> For example, in the Siemens Extra 330 LE<\/a> aerobatic aircraft, in which two battery systems each consisting of 3024 cells have an output of up to 260 kW.<\/span><\/span><\/span><\/p>\n<\/div>\n\t\t<\/div><\/div><\/div>

Battery module for high power<\/h3>

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High-performance battery for the Siemens Extra 330 LE<\/h3>

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Finished high-performance battery in a steel frame<\/h3>

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Copper is an excellent connector material for round cells when a low-resistance connection is required. Due to the extremely high electrical conductivity of the copper material, a lower voltage drop occurs at high currents. The heating resulting from line losses is also lower. Heat loss from the cells is better dissipated into the environment through […]<\/p>\n","protected":false},"author":3,"featured_media":0,"parent":22,"menu_order":0,"comment_status":"closed","ping_status":"closed","template":"","meta":{"footnotes":""},"class_list":["post-577","page","type-page","status-publish","hentry","post"],"yoast_head":"\nCopper welding on cylindrical cells - Welcome to Air Energy<\/title>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/www.airenergy.de\/en\/leistungen\/copper-welding-on-cylindrical-cells\/\" \/>\n<meta property=\"og:locale\" content=\"de_DE\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Copper welding on cylindrical cells - Welcome to Air Energy\" \/>\n<meta property=\"og:description\" content=\"Copper is an excellent connector material for round cells when a low-resistance connection is required. 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