Lightweight tool allows easy manipulation of battery cans and tab materials

By James Tod, AMADA MIYACHI UK

Improving battery technology is necessary to respond to the global focus on electric vehicle (EV) technology. One way of improving battery pack performance is by replacing existing nickel battery tabs with copper material. Unfortunately, it has been difficult and/or expensive to weld copper using traditional methods. Now, a new touch retract tungsten inert gas (TIG) welding technology has been developed that allows safer and easy manipulation of battery cans and tab materials in a bench-top, research and development (R&D) environment. Using typical prototype tooling, the system is especially suitable for R&D on battery pack concepts and assembly, low-medium volume battery pack manufacturing, and battery pack repair/rework applications. Longer term uses include maritime, aviation, energy, and consumer goods.

Battery pack welding for EV market

Market analysis suggests that electric cars will cost the same as gasoline vehicles within eight years, pushing the global EV fleet to 530 million vehicles by 2040. About 90 gigawatt hours of EV lithium-ion battery manufacturing capacity is currently online, and this is set to rise to 270 gigawatt hours by 2021.

Switching from nickel to copper tabs for battery connections can increase EV battery life by up to 20 percent, so manufacturers are looking for the most cost-effective technologies to do so. Available battery pack welding technologies include traditional resistance welding, laser welding, and TIG welding.

Resistance welding is considered the standard for welding non-copper electrical components. Quick, simple, and very low cost, resistance welding has many benefits. Unfortunately, copper is harder to resistance weld. Resistance welding relies on the inherent electrical resistance in a material to create heat, which melts the metal and creates the bond. Copper is conductive to electricity, so it does not generate much heat; what heat it does generate is largely directed away from the area.

Laser welding works well for welding copper to tabs, but it can be an expensive solution. In addition to the cost of the lasers themselves, tooling equipment is necessary to hold the parts firmly in place. Because no mechanical force holds the parts together, tooling is required to ensure the proper contact before welding. The higher cost makes laser welding copper tabs best for high volume manufacturing factory production lines, not lower volume R&D applications.

Micro arc welding is a highly efficient method for generating localised heat. With TIG welding, the operator strikes an arc on an electrode. Operators point the electrode at the part to be welded, and then use a high voltage to create a spark (similar to lightning) between the electrode and the material. That arc generates quite a bit of heat, which melts the material together and forms a strong bond. Due to the high voltage used, traditional TIG welding is safer and most effective in machines where there is no physical contact – and when it is in the hands of a skilled operator who can control the arc gap. Using traditional high voltage TIG welding in R&D applications, hand held assembly, and low volume manufacturing presents health and safety problems. While those working in these settings may hold a PhD in battery science, they are not likely to be highly skilled TIG welders.

Recently, a new type of touch retract TIG welding torch technology has been developed that does not involve physical contact. The electrode is pulled back with an electronic solenoid, eliminating the high voltage ignition and making it a lot safer and easier to use. The touch retract torch is extremely repeatable. It does not require maintaining a given distance – pulling back at the same distance every time. In effect, anyone can create a repeatable weld.

 Figure 1 shows the three steps in the touch retract TIG torch process. (Left – approach) The electrode extends below the nozzle, enabling the operator to see where they are placing the weld. (Center – compression) During the compression step, the operator pushes down on the torch. A small current detects that the electrode is in contact with the workpiece. (Right – retraction) In the final retraction phase, the electrode retracts, drawing an arc with an intermediate current. When the mechanism is at full travel, the main welding current is applied.

2019 07 08 091728 Figure 1

Advantages of the new TIG torch technology for battery pack welding

The new TR-T0016A touch retract torch manufactured by AMADA MIYACHI, was developed primarily for use in battery pack welding for electric vehicle (EV) applications, in which hundreds of small cells are welded together into modules. In the past, nickel bus bars were used to join up positive and negative terminals, but new designs are seeking to join copper strips to the battery can. The new touch retract TIG torch welder offers effective welding of copper with relative ease compared to traditional resistance welding techniques. For hand assembly, touch retract starting is a safer method than high voltage. It also costs less than a typical laser system.

For example, major global automobile manufacturers seeking to weld their own battery packs may opt for a robotic laser system that costs about half a million dollars and is used in an automated production line. But for those looking to conduct rapid evaluation of battery pack designs or other R&D work, and for production of small volume prototypes, small to medium scale battery pack repair or rework, or even Formula 1 racing teams, the hand held touch retract TIG torch welder is an attractive solution that works well. It can also be a tool for investigating and fixing process issues. Rather than simply disposing of parts, the touch retract torch can be used to fix loose joints.

Figure 2Figure 2

Figure 2 shows the new AMADA MIYACHI TR-T0016A, supplied in a plastic carry case, which includes the welding torch fitted with cables, instruction manual, spare nozzle, spare ceramic, spare spring, spare electrode Hex wrench, and spanner.

The flexible nature of the retractable TIG torch allows concepts to be quickly manufactured and tested so it fits well with R&D organizations working on the evaluation and production process design of their battery pack concepts. The technology offers a high repeatability rate with one weld per second. It also has a narrow (7 mm) nozzle and protruding electrode for better weld location control.

While designed for hand use, the touch retract TIG torch can be incorporated into an automated manufacturing line, so it would be appropriate for low-medium volume production applications. For example, it would be a good option for university spinoffs that have done R&D and are now looking to scale up for production, and want the repeatability of an automated machine.

The new system has been extensively tested for welding typical battery tab materials (copper, nickel, and aluminium, up to a thickness of 0.5 millimetres (mm)) onto 18650 and 21700 battery can material. It can also be used to join other metals, including stainless steel, gold plated stainless steel, and many others.

Figure 3Figure 3

Figure 3 shows an example of a battery tab welding application.

Safer and cost-effective solution for R&D environments

Offering ease of joining copper strips on a battery and a high repeatability rate, the new lightweight, handheld tool TIG torch can be used for rapid design evaluation of battery pack concepts, small-medium scale manufacturing, and manufacturing scale-up. Equally good for hand production and rework and automation, the new product features a low voltage arc to encourage operator safety.

Published inEquipment

Lightweight tool allows easy manipulation of battery cans and tab materials

Improving battery technology is necessary to respond to the global focus on electric vehicle (EV) technology. One way of improving battery pack performance is by replacing existing nickel battery tabs with copper material. Unfortunately, it has been difficult and/or expensive to weld copper using traditional methods. Now, a new touch retract tungsten inert gas (TIG) welding technology has been developed that allows safer and easy manipulation of battery cans and tab materials in a bench-top, research and development (R&D) environment. Using typical prototype tooling, the system is especially suitable for R&D on battery pack concepts and assembly, low-medium volume battery pack manufacturing, and battery pack repair/rework applications. Longer term uses include maritime, aviation, energy, and consumer goods.

Battery pack welding for EV market

Market analysis suggests that electric cars will cost the same as gasoline vehicles within eight years, pushing the global EV fleet to 530 million vehicles by 2040. About 90 gigawatt hours of EV lithium-ion battery manufacturing capacity is currently online, and this is set to rise to 270 gigawatt hours by 2021.

Switching from nickel to copper tabs for battery connections can increase EV battery life by up to 20 percent, so manufacturers are looking for the most cost-effective technologies to do so. Available battery pack welding technologies include traditional resistance welding, laser welding, and TIG welding.

Resistance welding is considered the standard for welding non-copper electrical components. Quick, simple, and very low cost, resistance welding has many benefits. Unfortunately, copper is harder to resistance weld. Resistance welding relies on the inherent electrical resistance in a material to create heat, which melts the metal and creates the bond. Copper is conductive to electricity, so it does not generate much heat; what heat it does generate is largely directed away from the area.

Laser welding works well for welding copper to tabs, but it can be an expensive solution. In addition to the cost of the lasers themselves, tooling equipment is necessary to hold the parts firmly in place. Because no mechanical force holds the parts together, tooling is required to ensure the proper contact before welding. The higher cost makes laser welding copper tabs best for high volume manufacturing factory production lines, not lower volume R&D applications.

Micro arc welding is a highly efficient method for generating localised heat. With TIG welding, the operator strikes an arc on an electrode. Operators point the electrode at the part to be welded, and then use a high voltage to create a spark (similar to lightning) between the electrode and the material. That arc generates quite a bit of heat, which melts the material together and forms a strong bond. Due to the high voltage used, traditional TIG welding is safer and most effective in machines where there is no physical contact – and when it is in the hands of a skilled operator who can control the arc gap. Using traditional high voltage TIG welding in R&D applications, hand held assembly, and low volume manufacturing presents health and safety problems. While those working in these settings may hold a PhD in battery science, they are not likely to be highly skilled TIG welders.

Recently, a new type of touch retract TIG welding torch technology has been developed that does not involve physical contact. The electrode is pulled back with an electronic solenoid, eliminating the high voltage ignition and making it a lot safer and easier to use. The touch retract torch is extremely repeatable. It does not require maintaining a given distance – pulling back at the same distance every time. In effect, anyone can create a repeatable weld.

 Figure 1 shows the three steps in the touch retract TIG torch process. (Left – approach) The electrode extends below the nozzle, enabling the operator to see where they are placing the weld. (Center – compression) During the compression step, the operator pushes down on the torch. A small current detects that the electrode is in contact with the workpiece. (Right – retraction) In the final retraction phase, the electrode retracts, drawing an arc with an intermediate current. When the mechanism is at full travel, the main welding current is applied.

Fig 1. Three step approach, compression, retractionFig 1. Three step approach, compression, retraction

Advantages of the new TIG torch technology for battery pack welding

Figure 2 shows the new AMADA MIYACHI TR-T0016A, supplied in a plastic carry case, which includes the welding torch fitted with cables, instruction manual, spare nozzle, spare ceramic, spare spring, spare electrode Hex wrench, and spannerFigure 2 shows the new AMADA MIYACHI TR-T0016A, supplied in a plastic carry case, which includes the welding torch fitted with cables, instruction manual, spare nozzle, spare ceramic, spare spring, spare electrode Hex wrench, and spannerThe new TR-T0016A touch retract torch manufactured by AMADA MIYACHI, was developed primarily for use in battery pack welding for electric vehicle (EV) applications, in which hundreds of small cells are welded together into modules. In the past, nickel bus bars were used to join up positive and negative terminals, but new designs are seeking to join copper strips to the battery can. The new touch retract TIG torch welder offers effective welding of copper with relative ease compared to traditional resistance welding techniques. For hand assembly, touch retract starting is a safer method than high voltage. It also costs less than a typical laser system.

For example, major global automobile manufacturers seeking to weld their own battery packs may opt for a robotic laser system that costs about half a million dollars and is used in an automated production line. But for those looking to conduct rapid evaluation of battery pack designs or other R&D work, and for production of small volume prototypes, small to medium scale battery pack repair or rework, or even Formula 1 racing teams, the hand held touch retract TIG torch welder is an attractive solution that works well. It can also be a tool for investigating and fixing process issues. Rather than simply disposing of parts, the touch retract torch can be used to fix loose joints.

The flexible nature of the retractable TIG torch allows concepts to be quickly manufactured and tested so it fits well with R&D organizations working on the evaluation and production process design of their battery pack concepts. The technology offers a high repeatability rate with one weld per second. It also has a narrow (7 mm) nozzle and protruding electrode for better weld location control.

While designed for hand use, the touch retract TIG torch can be incorporated into an automated manufacturing line, so it would be appropriate for low-medium volume production applications. For example, it would be a good option for university spinoffs that have done R&D and are now looking to scale up for production, and want the repeatability of an automated machine.

The new system has been extensively tested for welding typical battery tab materials (copper, nickel, and aluminium, up to a thickness of 0.5 millimetres (mm)) onto 18650 and 21700 battery can material. It can also be used to join other metals, including stainless steel, gold plated stainless steel, and many others.

Figure 3 shows an example of a battery tab welding application.Figure 3 shows an example of a battery tab welding application.

Safer and cost-effective solution for R&D environments

Offering ease of joining copper strips on a battery and a high repeatability rate, the new lightweight, handheld tool TIG torch can be used for rapid design evaluation of battery pack concepts, small-medium scale manufacturing, and manufacturing scale-up. Equally good for hand production and rework and automation, the new product features a low voltage arc to encourage operator safety.

Published inEquipment

AMADA MIYACHI announces that it now offers the new TR-T0016A Touch Retract Welding Torch, ideal for rapid design evaluation of electric vehicle battery pack concepts in research and development settings, low to medium volume battery pack manufacturing, and battery pack repair and rework applications. The TR-T0016A Touch Retract Welding Torch is a great choice for those scaling up from R&D to manufacturing, offering ease of integration and automation.

The TR-T0016A Touch Retract Torch is a lightweight, handheld tool that allows easy manipulation of battery cans and tab materials in a bench-top, R&D environment. The system can be used with typical prototype tooling. The system has been extensively tested for welding copper, nickel, and aluminium battery tab materials up to a thickness of 0.5 millimetres (mm) onto 18650 and 2170 battery can material.

2019 02 25 093004

Compared to traditional resistance welding technologies, the TR-T0016A Touch Retract Torch can achieve effective welding of copper with relative ease. Its low voltage operation also offers safety advantages for hand assembly applications compared to many tungsten inert gas (TIG) systems.

At a lower cost than a typical laser system, the system is a more affordable option for low volume battery pack prototyping, racing vehicles, and small to medium scale battery pack rework. The flexible TR-T0016A enables battery pack concepts to be quickly manufactured and tested. It can also be incorporated into an automated manufacturing line, making the TR-T0016A appropriate for low to medium volume niche automotive production applications.

About Amada Miyachi Europe

Amada Miyachi Europe is a leading manufacturer of equipment and systems for Laser Welding, Laser Marking, Laser Cutting, Resistance Welding, Hermetic Sealing and Hot Bar Reflow Soldering & Bonding.  We customize our products around specific micro-joining applications for all our customers around the globe. Amada Miyachi Europe product markets include medical devices, battery, automotive, solar industry, electronic components and aerospace.  We are an ISO9001 certified company. Contact Amada Miyachi Europe at This email address is being protected from spambots. You need JavaScript enabled to view it.. Find out more about the company’s products and services at www.amadamiyachi.eu

Published inEquipment

AMADA MIYACHI announces that it now offers the new TR-T0016A Touch Retract Welding Torch, ideal for rapid design evaluation of electric vehicle battery pack concepts in research and development settings, low to medium volume battery pack manufacturing, and battery pack repair and rework applications. The TR-T0016A Touch Retract Welding Torch is a great choice for those scaling up from R&D to manufacturing, offering ease of integration and automation.

The TR-T0016A Touch Retract Torch is a lightweight, handheld tool that allows easy manipulation of battery cans and tab materials in a bench-top, R&D environment. The system can be used with typical prototype tooling. The system has been extensively tested for welding copper, nickel, and aluminium battery tab materials up to a thickness of 0.5 millimetres (mm) onto 18650 and 2170 battery can material.

2019 02 25 093004

Compared to traditional resistance welding technologies, the TR-T0016A Touch Retract Torch can achieve effective welding of copper with relative ease. Its low voltage operation also offers safety advantages for hand assembly applications compared to many tungsten inert gas (TIG) systems.

At a lower cost than a typical laser system, the system is a more affordable option for low volume battery pack prototyping, racing vehicles, and small to medium scale battery pack rework. The flexible TR-T0016A enables battery pack concepts to be quickly manufactured and tested. It can also be incorporated into an automated manufacturing line, making the TR-T0016A appropriate for low to medium volume niche automotive production applications.

About Amada Miyachi Europe

Amada Miyachi Europe is a leading manufacturer of equipment and systems for Laser Welding, Laser Marking, Laser Cutting, Resistance Welding, Hermetic Sealing and Hot Bar Reflow Soldering & Bonding.  We customize our products around specific micro-joining applications for all our customers around the globe. Amada Miyachi Europe product markets include medical devices, battery, automotive, solar industry, electronic components and aerospace.  We are an ISO9001 certified company. Contact Amada Miyachi Europe at This email address is being protected from spambots. You need JavaScript enabled to view it.. Find out more about the company’s products and services at www.amadamiyachi.eu

Published inSheet Metal

AMADA MIYACHI AMERICA INC., a leading manufacturer of resistance welding, laser welding, marking, cutting, and micro machining equipment and systems, announces an update to its Series 320 Electronic Weld Head System, which increases the maximum weld force to 7.0 lb. (3175 gm) with a maximum follow up force of 7.75 lb. (3520 gm). Now the Series 320 can handle an even wider range of applications requiring precise position and force control.

Series 320 is ideal for safety critical applications in the medical, aerospace, precision electronics, and automotive markets. With the expanded force range, the Series 320 is a good choice for fine wire welding like squib wires as well as hearing aid components, electronic components, and implantable medical devices.

2019 01 23 083915

Series 320 meets the process demands of microelectronics manufacturing, but is robust enough to endure industrial environments. It can be configured with in-line or offset opposed electrodes to tailor the weld head for specific applications. With exceptionally accurate force and position parameters, the Series 320 provides outstanding process control and measurement. The weld-to-displacement feature stops the weld precisely during collapse.

Also offered is an initial part detection feature that detects missing or extra parts. Displacement limits facilitate monitoring of both initial and final part thickness.

In addition, the software has been updated to include a low force dress mode for preparation and cleaning of electrodes. This feature eases the routine maintenance required to get precise, repeatable results.

The updated Series 320 is available with linear motion or two level footswitch options. A user friendly I/O makes for easy integration with a PLC. Four programmable relay outputs facilitate precise process control.

For more information, visit the AMADA MIYACHI AMERICA website at http://www.amadamiyachi.com/.

About AMADA MIYACHI AMERICA

Since 1948, AMADA MIYACHI AMERICA, INC. has worked to achieve one goal: to solve customer’s manufacturing challenges. Knowing there is no one solution that fits all, the company strives to provide customers with innovative and reliable manufacturing technology solutions in an effort to be their single source provider. AMADA MIYACHI AMERICA manufactures equipment and systems for resistance welding, laser welding, laser marking, laser cutting, hermetic sealing and hot bar reflow soldering and bonding. The company serves a wide range of markets including medical devices, battery, aerospace, automotive and electronic components.  AMADA MIYACHI AMERICA is an ISO9001 certified company. Contact AMADA MIYACHI AMERICA at This email address is being protected from spambots. You need JavaScript enabled to view it.. Learn more about the company’s products and services at www.amadamiyachi.com.

Published inEquipment

Using aluminum and copper for battery tab to cell welding improves electrical efficiency and battery module/battery pack performance

As the world becomes more mobile and components become smaller, the demand for longer lasting batteries has been increasing. Increasing battery life requires lower electrical resistance to reduce loss. New laser sources, including single mode fiber lasers and lasers with nanosecond pulses, provide an important opportunity to reduce resistance by enabling the joining of aluminum and copper battery tab material – reducing resistance and improving performance. Tests have shown the technology works well with metal thickness of less than 0.25 millimeters (mm), providing good pull and peel strengths in these dissimilar joints.

A brief history of battery pack manufacturing

This article concentrates on commonly used cylindrical cell batteries to explain the concept of dissimilar metal joining with lasers. The same technology can also be used for some other battery types, including pouch cells, which typically feature one aluminum and one copper tab that requires an electrical connection to the busbars.

Most cylindrical battery cans are made of cold rolled steel (CRS) that has been nickel-plated for corrosion resistance. Figure 1 shows one of the most common cells – lithium ion 18650. To connect multiple cells together, or connect one cell to outside equipment, a strap or tab must be connected to the battery.

2018 07 27 090431

Historically, tabs were made of nickel, stainless steel, nickel plated steel, or Hilumin® (an electro nickel-plated diffusion annealed steel strip) due to their similar properties and the ease with which they can create a fusion bond. These materials join well in a variety of welding techniques, including resistance spot welding, pulsed arc welding, and laser welding.

As the demand for battery and battery pack performance increases, new materials are being considered to improve current delivery. When we assume a certain type of battery is being used, the material of the two terminals of the battery is a given and can’t be changed by the battery module manufacturer. So a further optimizing of the electrical performance of the battery module requires consideration of dissimilar metal bonding to allow the usage of highly electrical conductive battery tabs to the battery terminals.

The benefits of dissimilar joining for battery applications

Designers of battery packs for hybrid and electric automobiles, motorcycles, buses, heavy industrial vehicles, and hand-held power tools are looking for more energy to support the vehicle or device and increase its life. To do this, they must change the batteries’ electrode, isolator, and electrolyte, and lower its internal resistance to reduce energy losses on a battery cell level. The lower the loss, the more efficiently energy is stored in the battery. These improved batteries store more energy and can also charge and discharge faster, as measured by the battery’s “C” rate– the ratio between the charge/discharge acceptance and its capacity.

2018 07 27 090455The higher voltages and currents generated by improved batteries means the battery interconnection (battery tab) must improve its electrical conductivity. The higher electrical conductivity results in lower electrical losses when charging and discharging, so more electrical energy is available for the vehicle or device powered by the pack. By improving the electrical conductivity, the pack also stays cooler during operation, which provides additional performance and battery lifetime benefits. Last, but not least, improving battery performance lowers costs, because fewer batteries are required for a particular performance level.

The three options for improving battery interconnect performance are using thicker tabs to carry more current, using different tab materials (for example, copper or aluminum) with higher conductivity, or creating a larger tab to battery pole contacting area.

In the past, steel and nickel-based materials were commonly welded to the CRS terminals. However, more recently, as batteries have move towards higher capacity and higher “C” values, designers began looking at using aluminum or copper materials for tabs to reduce electrical losses. See Figure 2.

Challenges of using traditional Nd:YAG lasers for welding dissimilar metals

This rise in the use of dissimilar material welding comes with a variety of challenges for traditional welding options like pulsed Nd:YAG (neodymium-doped yttrium aluminum garnet) lasers, which typically make spots that are 0.5 mm in diameter with one pulse. Each weld pulse takes between 1 and 10 milliseconds; depending on its power level, the laser can generate about 10 of these pulses every second. To create a joint with sufficient electrical and mechanical properties, between 2 and 50 welding spots must be placed on each battery pole. See Figure 3.

2018 07 27 090515

This method worked well for the traditional battery tab materials because of their weldability. However, welding of dissimilar materials is significantly more challenging because of:

  • Different melting temperatures (see Table 1)
  • Different thermal expansion coefficients
  • Different absorption coefficient of laser light
  • Incompatible chemistry and atomic structures

Joining aluminum to stainless steel has always been an impossible welding combination. The mixing of these two metals creates a brittle intermetallic zone leading to weld cracks.

2018 07 27 090549

Innovative laser welding technologies

New laser technologies are rewriting the textbooks on which materials can be joined together. Single mode fiber lasers and lasers with nanosecond pulses are joining new combinations of metal that were previously not considered compatible.

The single mode laser can be focused to spot diameters of 20-50 microns – smaller than the diameter of a human hair! This makes a very small welding line of 20-50 microns wide, which can be pulsed like “a hot knife through butter” to make a weld. The linear speed of this laser beam movement is typically in the 100 to 1000 mm/sec (4-inch-40-inch/second) range. See Figure 4.

2018 07 27 090607


To create sufficient joint area, the length of this joint needs to be 10 to 100 mm per battery pole. To fit this onto the 3 to 6 mm diameter available on a battery pole, the line must be in a spiral shape or concentric circles, rather than spots. Using a galvo scanning weld head, the total weld can be very fast; it takes about 50 milliseconds of weld time.

Another method of welding dissimilar metals is to concentrate the laser energy in time by using nanosecond pulsed fiber welding instead of the traditional millisecond pulse. The weld pulses are typically 100,000 times shorter, providing energy in a much shorter period. This increases the laser peak power level by the same amount. The spot size is also very small, about 30 to 40 microns. The high peak power on a small area results in such a high peak power density that all metals are molten. This process can be best described as “pushing a hot needle in the material and pulling it out again.” The spots are very small, so a great many spots are needed, typically 10,000 or more. As the timeframe for creating one spot is very small, the laser can be fired at high repetition rates, typically 30 kilohertz (kHz) and above.

2018 07 27 090628The best method of getting enough weld spots with the nanosecond laser on a small area like a battery pole is to make a line coiled into a spiral. This spiral is typically welded from the inside to the outside, so the laser beam always “sees” a fresh and cold piece of metal in front of it. If the laser went from the outside to the inside, there would be heat build-up and increased penetration depth towards the center, as the part heats up during the welding.

Figure 5 shows an example of a spiral weld made on aluminum tab material. Testing showed single layer shear strengths of around 44 N (10 pounds) and double layer shear strength at around 88 N (20 lbs.).

Figure 6 is an application photo showing an aluminum battery tab welded to a nickel-plated cold rolled steel can using the spiral weld technique. A closer look at the cross sections reveals that the spot welds do not show the characteristic form of conventional pulsed spot welds – they more closely resemble multi‐staking. The intermetallic zone was less than 10 microns. Pull strength was good and peel strength was adequate. There was barbed solidification of aluminum into steel.

2018 07 27 090711

One example of the new technology is AMADA MIYACHI’s 70-Watt LMF70-HP OEM fiber laser, which can be integrated into the LMWS pulsed fiber laser welding system. The new technology is an advanced processing system for welding battery cans with wall thicknesses of 300-350 microns. It features shorter pulses, resulting in less mixing of materials, and hence less of an intermetallic zone and less brittleness with aluminum tab materials. This laser solution is good for contract manufacturing settings, where operators may be producing one product one day and something different the next. The XY galvo program quickly positions welds; a new program can be loaded in as little as five minutes, and operators can be ready to start the next product.

New battery tab welding technologies widen the design portfolio by providing good solutions for dissimilar material joining

The new nanosecond pulsed fiber laser and the single mode fiber laser provide opportunities for dissimilar metal joining and show great potential as a solution for welding battery tabs to cells. Allowing for aluminum and copper tab material, which reduce electrical resistance and improve battery performance, the new technology shows great promise for a wide range of industries.

Published inProduction

AMADA MIYACHI EUROPE announces the availability of the LMWS Pulsed Fiber Laser Welding System. Paired with the ML-7370D 70W pulsed fiber laser, the LMWS offers an advanced processing system ideal for welding dissimilar metals, including copper (Cu) to aluminum, aluminum to stainless steel (SS) and steel, and copper to stainless steel. The LMWS enables the joining of aluminum and copper battery tab material – reducing resistance and improving performance. It is also a good choice for Cu-SS thin sheet welding and plastic welding.

2018 07 27 084134With the ML-7370D 70W pulsed fiber laser, more electrical energy is available for the newest generation of smaller, lighter, more cost-effective, and reliable battery packs used in hybrid and electric automobiles, motorcycles, buses, and heavy industrial vehicles, as well as hand-held power tools. By improving the electrical conductivity, the pack stays cooler during operation. This provides additional benefits to both pack performance and battery lifetime. Improving battery performance also lowers battery pack costs, because fewer batteries are required for a particular performance level. Weight and size of the pack is similarly positively influenced.

Tests have shown that the new high-speed fiber laser welding system works well for welding thin metals up to 250 microns thick. This is an ideal tab thickness for battery cans with wall thicknesses of 300-350 microns. The new technology features shorter pulses with a higher peak power than traditional laser options. The shorter pulse results in less mixing of materials, and hence less of an intermetallic zone and less brittleness with copper and aluminum tab materials.

The highly configurable, compact LMWS unit is designed for lean manufacturing. By simply changing the settings, this laser can also mark, engrave, cut, drill, and ablate thin materials. The versatile high-power, high-speed laser LMWS is available with a variety of integration options to match process needs. It comes standard with an XY galvanometric scanner. A rotary stage option is also available. 

The LMWS unit can be used for several weld types, including single point object arrays, basic shapes (rectangle, circle, spiral), wobble function and vector graphics including CAD and line-drawings, and logos.

The LMWS complies with IEC13849 – 1, category 3 PLd safety circuitry requirements for ease of usage and integration into any quality system.

Published inEquipment

Perfect benchtop operation and designed for lean manufacturing

2018 05 14 102544Amada Miyachi Europe announces its new LMWS low-cost Laser Marking Workstation, specifically designed for benchtop operation. A major facelift to Miyachi’s LMW2020 and LMW2030 marker workstations, the LMWS features a fresh design, available as an operator-safe Class 1 or open Class 4, with improved functionality. Designed for lean manufacturing, LMWS offers the widest range of marking capability in its class.

The versatile and easily configurable LMWS is ideal for marking metals, ceramics, and many plastics, and also has cutting, drilling, and welding capabilities. Requiring only minimal workspace, the updated unit is perfect for low volume production and research and development environments in the automotive, medical, aerospace, electronic components, and battery industries. Although the design has been modernized and several features added, the new LMWS is available at a reduced price point.

Standard LMWS models are powered by Miyachi’s popular 10-50W ML fiber laser markers and use the same graphic user interface for easy transfer from prototype to production phase. Although separable from the base LMF, the two machines are designed to function as one unit.

The fast and precise motorized Z axis and rotary stage make for easy adjustment of part and focus. The spring loaded manual door opens for easy 270 degree access to parts and tooling, and the large viewing window allows for easy mark monitoring. The LMWS is equipped with F-Theta 100mm, 160mm and 254mm lens options for marking various parts and sizes. The LMWS features an optional compact motorized rotary for marking cylindrical parts, as well as an optional programmable Z-axis.

Published inMachinery

Perfect benchtop operation and designed for lean manufacturing

2018 04 20 072535Amada Miyachi Europe announces its new LMWS low-cost Laser Marking Workstation, specifically designed for benchtop operation. A major facelift to Miyachi’s LMW2020 and LMW2030 marker workstations, the LMWS features a fresh design, available as an operator-safe Class 1 or open Class 4, with improved functionality. Designed for lean manufacturing, LMWS offers the widest range of marking capability in its class.

The versatile and easily configurable LMWS is ideal for marking metals, ceramics, and many plastics, and also has cutting, drilling, and welding capabilities. Requiring only minimal workspace, the updated unit is perfect for low volume production and research and development environments in the automotive, medical, aerospace, electronic components, and battery industries. Although the design has been modernized and several features added, the new LMWS is available at a reduced price point.

Standard LMWS models are powered by Miyachi’s popular 10-50W ML fiber laser markers and use the same graphic user interface for easy transfer from prototype to production phase. Although separable from the base LMF, the two machines are designed to function as one unit.

The fast and precise motorized Z axis and rotary stage make for easy adjustment of part and focus. The spring loaded manual door opens for easy 270 degree access to parts and tooling, and the large viewing window allows for easy mark monitoring. The LMWS is equipped with F-Theta 100mm, 160mm and 254mm lens options for marking various parts and sizes. The LMWS features an optional compact motorized rotary for marking cylindrical parts, as well as an optional programmable Z-axis.

About Amada Miyachi Europe

Amada Miyachi Europe is a leading manufacturer of equipment and systems for Laser Welding, Laser Marking, Laser Cutting, Resistance Welding, Hermetic Sealing and Hot Bar Reflow Soldering & Bonding.  We customize our products around specific micro-joining applications for all our customers around the globe. Amada Miyachi Europe product markets include medical devices, battery, automotive, solar industry, electronic components and aerospace.  We are an ISO9001 certified company. Contact Amada Miyachi Europe at This email address is being protected from spambots. You need JavaScript enabled to view it.. Find out more about the company’s products and services at www.amadamiyachi.eu

Laser Welding Workstations for precision laser spot and seam welding

AMADA MIYACHI EUROPE announces the availability of its MIYACHI EAPRO NOVA3 Laser Welding Workstations, ideal for precision spot- or seam welding of metal parts, including medical, automotive, electronic, and aerospace components.

2017-01-10 092352The NOVA3 is an excellent choice for seam sealing of medical devices and high frequency aerospace radar components, spot welding of small mechanical parts and battery housings, as well as hermetic seam welding of sensors, batteries and battery packages. The MIYACHI laser welders can join a wide range of stainless steels, nickel alloys, titanium, aluminium, and copper.

The modular, flexible, lean-manufacturing-ready NOVA3 Series Laser Welding Workstations feature CE-approved, Class 1 eye-safe enclosures. The stable and ergonomic platform facilitates continuous production and stress-free, concentrated, and effective operators. An integrated touchscreen enables easy programming.

Comprised of high performance ruggedized industrial laser equipment, the NOVA3 is customizable to specific production requirements. It can be equipped with pulsed Nd-YAG lasers up to 600W, continuous wave fibre lasers up to 5000W and quasi-continuous wave (pulsed) fibre lasers up to 600W average power. Manual, pneumatic, and motorized door configurations are available, with horizontal or vertical opening direction. The NOVA3 offers servo motor driven axis (XYZ) CNC motion.

More information on AMADA MIYACHI EUROPE’S NOVA3 Series Laser Welding Workstations can be found at http://www.amadamiyachieurope.com/products/laser-welding/nova3-laser-welding-workstations/.

About Amada Miyachi Europe
AMADA MIYACHI EUROPE is a leading manufacturer of equipment and systems for Laser Welding, Laser Marking, Laser Cutting, Resistance Welding, Hermetic Sealing and Hot Bar Reflow Soldering & Bonding.  We customize our products around specific micro-joining applications for all our customers around the globe. AMADA MIYACHI EUROPE product markets include medical devices, battery, automotive, solar industry, electronic components and aerospace.  We are an ISO9001 certified company. Contact AMADA MIYACHI EUROPE at This email address is being protected from spambots. You need JavaScript enabled to view it..">This email address is being protected from spambots. You need JavaScript enabled to view it.. Find out more about the company’s products and services at www.amadamiyachi.eu.

Published inMachinery

Acquisition expands resistance welding product offerings, service expertise

AMYE LogoAmada Miyachi Europe announces that it has acquired Macgregor Welding Systems of Suffolk, England, a leader in the design and manufacture of precision micro joining equipment. MacGregor Welding Systems products include DC micro resistance welding equipment, micro pulsed arc and percussive arc and other welding technologies. With this acquisition, Amada Miyachi Europe is able to expand its range of products and services to meet the complete joining needs of its global customer base.

“Acquiring MacGregor creates an excellent opportunity to grow the business through the effective collaboration of the Amada Miyachi Europe and MacGregor teams and  to further develop new resistance welding and other welding products that meet the demands of modern industrial customers worldwide,” said David Fawcett, Group CEO and President Amada Miyachi America and Amada Miyachi Europe.

MacGregor Welding Systems produces resistance welding equipment. Additionally, the company designs and produces automatic and semi-automatic integrated resistance welding and related process systems, ranging in size and complexity from single work cells to fully-integrated, multi-station production line systems. The company’s in-house expertise in mechanical engineering, electronics design, software, and power system control engineering enables it to build customized equipment to meet each customer's specific requirements.

“We believe that the MacGregor Welding Systems has developed superior engineering capabilities, excellent customer relationships and a differentiated line of products which complement our line of business,” Fawcett added.

About Amada Miyachi Europe
Amada Miyachi Europe is a leading manufacturer of equipment and systems for Laser Welding, Laser Marking, Laser Cutting, Resistance Welding, Hermetic Sealing and Hot Bar Reflow Soldering & Bonding.  We customize our products around specific micro-joining applications for all our customers around the globe. Amada Miyachi Europe product markets include medical devices, battery, automotive, solar industry, electronic components and aerospace.  We are an ISO9001 certified company. Contact Amada Miyachi Europe at This email address is being protected from spambots. You need JavaScript enabled to view it..">This email address is being protected from spambots. You need JavaScript enabled to view it.. Find out more about the company’s products and services at www.amadamiyachi.eu

Published inProduction