24. Optimization of Battery Tab Interconnects by Micro-TIG Welding Using Simulated Annealing Algorithm and Response Surface Method

The present work is focused on the optimization of battery tab-to-tab joints for similar and dissimilar materials by using of aluminum (Al) and nickel-coated copper (Cu [Ni]) tabs. Micro-TIG welding is used as the joining technique for the battery tab interconnects. In this study, the Taguchi method is integrated with response surface methodology (RSM) and simulated annealing algorithm to solve the multi-response optimization problem. The adequacy of the models is tested using the output responses obtained using an analysis of variance (ANOVA). The optimum results for the output responses namely pulse duration of Al and Cu [Ni] tabs in terms of machining parameters namely thickness of tab materials and current for micro-TIG welding machine were determined. The computational results clearly show that the proposed optimization procedure has considerably improved the pulse duration values for obtaining better weld joints and low electrical resistance in the battery pack manufacturing.