Micro-resistance spot welding of cylindrical battery packets in FEM calculations

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Zygmunt Mikno
Szymon Kowieski


Due to the increasing demand for connecting cells in packets to power electric tools, bicycles and electric cars, the issue of the quality of battery cells with busbars joints with the use of external heat electrodes is particularly important. The paper presents the conditions of the joining process and modelling results using the DC source. Modelling was performed using commercially available Sorpas 3D software. It included checking the influence of the busbar shape, clamping force, electrode material, the shape of electrode face, the length of the tungsten inserts in the welding electrodes on the amount of heat and the diameter of the connections. Modelling results revealed in particular increased heat generation and connection diameters for electrodes with a smaller work surface, however, industrial practice shows that the electrode face diameter durability is limited and that the electrodes flatten - the electrode face diameter increases.


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How to Cite
Z. Mikno and S. Kowieski, “Micro-resistance spot welding of cylindrical battery packets in FEM calculations”, Weld. Tech. Rev., vol. 91, no. 8, pp. 43-52, Oct. 2019.
Original Articles


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