Rotary Friction Welding for EV Battery Lugs and Components Manufacturing

February 21, 2024

Friction welding joins materials through a compressive axial force and the movement of workpieces relative to each other, producing heat and plastically displacing the material to create a weld. Unlike other welding methods, friction welding does not require filler metals, flux materials, or shielding gases. Rotary friction welding involves one workpiece rotating around its axis while the other workpiece remains stationary, with an applied compressive force to join the two workpieces together. 

LPR Global offers hydraulic and CNC rotary friction welding machines for manufacturing automotive components. We also provide specialized machinery and manufacturing solutions for the automotive industry such as gantry robot systems and automatic seat assembly lines. Please visit our automotive industry page to learn more.

Rotary Friction Welding Advantages

Friction welding is a solid-state welding process, meaning the joining of the metals occurs without the metals reaching their melting points. Fusion welding methods, such as MIG welding or TIG (GTA or GTAW) welding require the metals to reach melting temperatures to create a welded connection. Friction welding circumvents the issues faced by fusion welding when joining metals with two different melting points and is a suitable welding method when joining two dissimilar metals. For example, copper has a melting point of 1085℃ and aluminum has a melting point of 660℃; fusion welding of these two metals would cause several issues such as asymmetrical welds due to the different melting points.

Friction welding is also a fast and highly repeatable process that can be automated. LPR Global carries a comprehensive catalogue of rotary friction welding machine models to meet your specific manufacturing needs, such as manufacturing bimetallic battery terminals or lugs. Our rotary friction welding machines are also highly customizable with options such as flash removal or an auto stopper to reduce cycle time.

Suitability of Friction Welding for EV and E-mobility Battery Components

E-Mobility or electric vehicle (EV) battery components such as battery lugs are often made of two different metal alloys due to the unique requirements of electric mobility. The electrical systems of EVs operate at a higher voltage and greater electric currents than those of conventional internal combustion engines (ICEs); however, they must also be lightweight for vehicle performance and cost competitive. Rotary friction welding enables two dissimilar metals to be joined, making it a suitable process for EV battery and electrical component manufacturing.

Specifically, bimetallic battery terminals and lugs made of copper and aluminum enable the electrical systems to benefit from the unique properties of each metal. Aluminum is lightweight and low-cost, while copper is highly conductive. By using a combination of both materials, e-mobility electrical systems can balance weight, cost, and conductivity to produce a vehicle that will meet the users’ requirements.

LPR Global Manufacturing for the Automotive Industry

LPR Global provides several types of rotary friction welding machines for manufacturing a wide range of automotive components including battery terminals, shock absorbers, and torque converters. 

Our expertise in the automotive industry allows us to provide additional manufacturing solutions including automotive body-in-white and chassis assembly systems, automotive interior trim machinery, and progressive stamping and forging dies. 

Please contact us for solutions to your automotive manufacturing needs.

Chaudhari, R., Parekh, R., & Ingle, A. (2014). Reliability of dissimilar metal joints using fusion welding: A Review. International Conference on Machine Learning, Electrical and Mechanical Engineering (ICMLEME’2014) Jan. 8-9, 2014 Dubai (UAE). https://doi.org/10.15242/iie.e0114050 

Uday, M. B., Ahmad Fauzi, M. N., Zuhailawati, H., & Ismail, A. B. (2010). Advances in friction welding process: A Review. Science and Technology of Welding and Joining, 15(7), 534–558. https://doi.org/10.1179/136217110×12785889550064