Electric vehicles and consumer electronics depend on high-capacity, highly efficient batteries, and the demand continues to rise. Critical to producing these batteries is the successful welding of foil-to-tab joints which are often made of dissimilar materials with dissimilar thicknesses. This process is complicated, and the failure of a single joint will compromise an entire battery pack.

A recurrent problem associated with the stamping of advanced
high strength steel (AHSS) is edge cracking. The shearing process damages and
hardens the edges of AHSS blanks, resulting in lower edge formability.

Recently, studies have been conducted at EWI on ways to improve edge formability of AHSS. Findings demonstrate that high-speed shearing can significantly improve edge formability. A paper by EWI associate Clare Gu, Effects of High-Speed Shearing on Edge Formability of AHSS, discusses the research and results of this work. To download this paper, simply complete the form on this page.

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If you would like to discuss this work with the author, contact [email protected].

To learn more about EWI’s work in sheet metal forming, visit https://ewi.org/capabilities/forming/