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04 NOVEMBER 2023 AL CIRCLE

Innovative Weld Solutions' new welding technology enables significant light-weighting of the electric vehicle

2MINS READ

Aluminium cables for high-current applications in electric vehicles can not only lower cost and weight but also improve the durability of the overall cable system and electric vehicle harness. So why haven't they been widely adopted? This article discusses the need for aluminium cables, what the industry has done so far, and how a new key welding technology from Innovative Weld Solutions LLC (IWSL) can enable the widespread use of aluminium cables for high-current applications in electric vehicles and their charging stations.

Stranded-wire aluminium cables would be much less expensive and significantly lighter than the copper cables being used presently. Unfortunately, industry efforts in trying to join them to connectors reliably have not been successful.

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Several methods, such as:

  • Cold/hot crimping after coating/plating the aluminium wires with tin, nickel, and other metals.
  • Friction welding/flash butt welding of solid connectors to stranded aluminium wires contained tightly in sleeves.
  • Laser welding of stranded aluminium wires in sleeves.
  • Soldering aluminium, including plasma/resistance soldering.
  • Ultrasonic welds were all tried unsuccessfully.

So, what has IWSL done differently? For starters, IWSL uses their ultra-high current resistance weld equipment to compact aluminium wires with an aluminium cove and melt them together with a connector into an entire weld nugget. Conducting and non-conducting portions of the weld tooling concentrate the weld current and heat at the connector-wire interface and melt them together to make this a robust manufacturing process.

This technology can be a revolutionary benefit to the electric bus, charging station cable and EV cable manufacturers in reducing the weight of the cable and its cost by several hundred US Dollars per vehicle.

The ultra-fast charging cable designs that presently need weight-lifting additions to the cable can now be manufactured with aluminium instead of copper to do away with the weight-lifting add-on.

Interested parties may contact IWSL for cooperative/collaborative work in this area.


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