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VIDEO DOI: https://doi.org/10.48448/f256-8040

technical paper

ICALEO 2023

October 17, 2023

Chicago, United States

High Speed Laser Cutting of Ultra-Thin Metal Foils for Battery Cell Production

keywords:

aluminum

thin folis

laser cutting

copper

Laser-based manufacturing has become a key enabling technology in the production of batteries and battery cells for e-mobility applications. Several applications, in fact, have already been industrialized for welding, cutting and stripping with lasers. Cutting, in particular, has to fulfil many very stringent constraints, such as: highly reflective materials (aluminum, copper), very low thickness (6-12 µm), on-the-fly processing, high quality of the cutting surface. According to those considerations, the present paper deals with the application of remote cutting of 8 µm thick aluminum and copper foils by means of a galvo scanner and two different fiber laser sources: single mode CW and nanosecond pulsed ones. The experimental activity is devoted to understanding the feasibility of the process and to point out pros and cons of the two different lasers involved. The cutting edges are analyzed by means of optical and SEM microscopy and confocal profilometry, in order to characterize the quality of the cutting, the presence of burr and the extension of the heat affected zone. The process is also characterized in terms of maximum achievable speed in order to understand the limits of both laser and galvo scanning system and some considerations are drawn on the role of the typical fine tuning parameters of the galvo scanner on the possibility to achieve high cutting speeds in an on-the-fly process.

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