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Welding processes recommended to automotive Member

Zytek Automotive is a specialist powertrain and vehicle engineering enterprise delivering value to its clients with innovative engineering solutions. Its focus has developed to cover the electric and hybrid-vehicle sector where it has a track record in solving complex engineering challenges for production vehicle projects.

As part of on-going development work, Zytek has a requirement to join four copper conductors each of approximate cross-section 9 x 1.25mm to a copper bus bar 9 x 5mm in cross-section. All parts are manufactured from Grade 2 copper and coated with a polyimide insulating material.

TWI reviewed the assembly and proposed three approaches likely to achieve acceptable joints in terms of electrical and mechanical performance. These were friction stir welding, tungsten inert gas (TIG) welding and soldering. Zytek decided to proceed with an investigation of TIG welding and soldering.

With regard to soldering, TWI recommended that a technique for stripping the polyimide coating and preparing the copper was developed so a consistent and even joint gap is achieved to assist with solder flow through the joint and retention within the joint.

For more information please email contactus@twi.co.uk.

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