CODELAB - Classification of defects and acceptance levels for increased electric safety in laser welded aluminium busbars

Purpose and goal

The project aims to increase the durability and electrical safety of electric vehicles by developing industry-wide guidelines for defect classification and acceptance levels in laser-welded aluminum bus bars for battery production. The goal is to reduce variation in testing, improve electrical performance, and support international standardization through experimentation, analysis, and knowledge dissemination.

Expected effects and result

The project is expected to result in new guidelines for defect management that can be integrated into international standards. This will lead to increased fire safety, longer battery life, reduced material scrap and more efficient production. The effects include strengthened Swedish competitiveness, more robust supply chains and increased competence in welding of current-carrying welds in, for example, battery manufacturing.

Planned approach and implementation

The project is implemented in five work packages with literature review, mapping of standards, industry dialogue, experimental testing and dissemination. Through workshops, testing and analysis, guidelines for defects in laser welded aluminum rails are developed. Scientific quality is ensured through hypothesis-driven methodology, validated measurement methods and continuous follow-up.