{"status":"ok","message-type":"work","message-version":"1.0.0","message":{"indexed":{"date-parts":[[2026,9,17]],"date-time":"2026-09-17T00:25:55Z","timestamp":1789604755872,"version":"build-2803163510"},"reference-count":30,"publisher":"MDPI AG","issue":"21","license":[{"start":{"date-parts":[[2022,10,25]],"date-time":"2022-10-25T00:00:00Z","timestamp":1666656000000},"content-version":"vor","delay-in-days":0,"URL":"https:\/\/creativecommons.org\/licenses\/by\/4.0\/"}],"funder":[{"DOI":"10.13039\/501100003725","name":"Regional Innovation Strategy (RIS)\u201d through the National Research Foundation of Korea (NRF) funded by the Ministry of Education (MOE)","doi-asserted-by":"publisher","award":["2021RIS-004"],"award-info":[{"award-number":["2021RIS-004"]}],"id":[{"id":"10.13039\/501100003725","id-type":"DOI","asserted-by":"publisher"}]},{"DOI":"10.13039\/501100003725","name":"Regional Innovation Strategy (RIS)\u201d through the National Research Foundation of Korea (NRF) funded by the Ministry of Education (MOE)","doi-asserted-by":"publisher","award":["NRF-2022R1A2C1003639"],"award-info":[{"award-number":["NRF-2022R1A2C1003639"]}],"id":[{"id":"10.13039\/501100003725","id-type":"DOI","asserted-by":"publisher"}]},{"DOI":"10.13039\/501100003725","name":"the National Research Foundation of Korea (NRF) grant funded by the Korean government (MSIT)","doi-asserted-by":"publisher","award":["2021RIS-004"],"award-info":[{"award-number":["2021RIS-004"]}],"id":[{"id":"10.13039\/501100003725","id-type":"DOI","asserted-by":"publisher"}]},{"DOI":"10.13039\/501100003725","name":"the National Research Foundation of Korea (NRF) grant funded by the Korean government (MSIT)","doi-asserted-by":"publisher","award":["NRF-2022R1A2C1003639"],"award-info":[{"award-number":["NRF-2022R1A2C1003639"]}],"id":[{"id":"10.13039\/501100003725","id-type":"DOI","asserted-by":"publisher"}]}],"content-domain":{"domain":[],"crossmark-restriction":false},"short-container-title":["Materials"],"abstract":"<jats:p>With advancements in the automotive industry, the demand for electric vehicles (EVs) has remarkably increased in recent years. However, the EV battery, which is a vital part of the EV, poses certain challenges that limit the performance of the EVs. The joining of dissimilar materials for different components affects the electrical and mechanical performances of EV batteries. Laser beam welding is a promising technique for joining Al and Cu for application in secondary battery fabrication because of the precise control over heat input and high process speed. However, the production of Al\u2013Cu joints remains challenging because of the differences between their thermal and metallurgical properties and the resulting formation of brittle and hard intermetallic compounds, which reduce mechanical and electric properties. Thus, it is vital to characterize the weld to improve joint performance and enhance the laser welding process. This study investigates the joining of an Al alloy (AA1050) with Ni-coated Cu using a continuous-wave Yb fiber laser. The evaluation of the weld morphology showed a correlation between the weld characteristics and process parameters (laser power and welding speed). The weld interface width and penetration depth into the lower sheet (Cu) both increased with increasing heat input. Optical microscopy of the weld cross-section revealed many defects, such as voids and cracks. Scanning electron microscopy (SEM) with energy-dispersive X-ray spectroscopy (EDS) was employed to examine the weld microstructure. The composition analysis revealed the presence of mixed morphology of Al\u2013Cu eutectic alloy (\u03b1-Al+\u0398-Al2Cu) phase in the form of dendrites in the weld fusion zone with traces of the highly brittle Al4Cu9 phase at a high heat input condition. Furthermore, the electrical contact resistance of the weld seam was measured to determine the correlation between heat input and resistance. In addition, Vickers microhardness measurements were performed on the weld cross-section to validate the SEM\/EDS results.<\/jats:p>","DOI":"10.3390\/ma15217463","type":"journal-article","created":{"date-parts":[[2022,10,25]],"date-time":"2022-10-25T23:50:28Z","timestamp":1666741828000},"page":"7463","update-policy":"https:\/\/doi.org\/10.3390\/mdpi_crossmark_policy","source":"Crossref","is-referenced-by-count":41,"title":["In-Depth Characterization of Laser-Welded Aluminum-and-Copper Dissimilar Joint for Electric Vehicle Battery Connections"],"prefix":"10.3390","volume":"15","author":[{"ORCID":"https:\/\/orcid.org\/0000-0002-1287-849X","authenticated-orcid":false,"given":"Sajid","family":"Ali","sequence":"first","affiliation":[{"name":"Department of Future Convergence Engineering, Kongju National University, 1223-24 Cheonandaero, Seobuk-gu, Cheonan 31080, Korea"}],"role":[{"vocabulary":"crossref","role":"author"}]},{"ORCID":"https:\/\/orcid.org\/0000-0003-2531-5386","authenticated-orcid":false,"given":"Joonghan","family":"Shin","sequence":"additional","affiliation":[{"name":"Department of Future Convergence Engineering, Kongju National University, 1223-24 Cheonandaero, Seobuk-gu, Cheonan 31080, Korea"},{"name":"Department of Mechanical and Automotive Engineering, Kongju National University, 1223-24 Cheonandaero, Seobuk-gu, Cheonan 31080, Korea"}],"role":[{"vocabulary":"crossref","role":"author"}]}],"member":"1968","published-online":{"date-parts":[[2022,10,25]]},"reference":[{"key":"ref_1","doi-asserted-by":"crossref","first-page":"107595","DOI":"10.1016\/j.optlastec.2021.107595","article-title":"A Review on Dissimilar Laser Welding of Steel-Copper, Steel-Aluminum, Aluminum-Copper, and Steel-Nickel for Electric Vehicle Battery Manufacturing","volume":"146","author":"Sadeghian","year":"2022","journal-title":"Opt. 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