Finite-element structural modelling of laser welds. Application to aluminium connections in Li-ion prismatic batteries
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This paper examines the impact of process parameters on the mechanical properties of laser-welded aluminum joints through both experimental and numerical studies. The experimental analysis involved hardness measurements, microstructural imaging, and cross-weld tensile tests conducted at temperatures up to 200 °C. The results showed that changes in the heat-affected zone (HAZ) significantly affected the mechanical properties, with a greater HAZ extension resulting in lower ultimate tensile strength (UTS) and increased engineering strain to failure. Thermal sensitivity remained consistent across both the base material and the welds. A cohesive zone model (CZM) was proposed to represent the mechanical behavior of the connections, including plasticity and fracture, in large-scale finite element models. The performance of the CZM and a shell element approach (SEA) were validated against experimental results and compared in a numerical study. The simulations demonstrated that the CZM has the potential to replace the SEA in simple load cases while still providing reasonable results for complex scenarios. Overall, both CZM and SEA can achieve adequate accuracy while reducing computational costs for large-scale structural modeling, making them well-suited for industrial applications.
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