Advanced Laser Welding Technology Produces Crack-Free Electric Vehicle Battery Housings Without the Need for Filler Wire
Revolutionary Laser Welding Technology Eliminates Fillers and Simplifies Production
The Fraunhofer Institute for Material and Beam Technology IWS in Dresden, Germany, has developed a groundbreaking laser welding technology that is set to revolutionize various industries. This innovative technology, developed by Denaliweld, eliminates the need for filler wire and produces streamlined, crack-free welds for electric vehicles, aerospace tanks, and heavy steel structures.
One of the most significant advantages of this new technology is its ability to handle even the most challenging welding tasks, such as joining hard-to-weld alloys or thick sections, with robustness and efficiency while reducing energy consumption, material use, and post-processing. In the automotive sector, a laser-welded aluminum battery housing at full component scale was successfully developed and tested as part of the EU's ALBATROSS initiative. The housing for a real vehicle model has already been integrated and tested using this technology.
The laser process reaches stable, low-heat welding even on three-dimensional contours, making it particularly useful for complex structures. Straightening large assemblies becomes unnecessary in many cases with this new technology. The process uses dynamic beam shaping to control the melt pool, reduce pores, and stabilize welds, ensuring crack-free, low-porosity seams at the absolute component scale.
The technology is also capable of welding high-strength 2,000-series aluminum alloys, known for their hot-cracking tendencies, without the use of filler material. This is a significant advancement, as these alloys are commonly used in the aerospace industry and for heavy steel structures.
The project, funded by the Development Bank of Saxony (SAB), targets bridge construction, wind energy, and shipbuilding applications. The combination of high-frequency scanner technology, flexible power modulation, and open system control enables design options and application perspectives that conventional arc welding cannot provide.
Early industry feedback shows strong interest in integrating the technology into existing production lines. The technology also offers substantial benefits in terms of production efficiency. The laser welding process reduces weld volume, saves up to 90 percent filler material, and largely eliminates distortion.
The new laser welding technology is already being used in the heavy steel industry to join profiles with wall thicknesses over 20 millimeters. The project's potential applications are vast, making it an exciting development for various industries.
