New energy power battery modules impose extremely high requirements on the reliability of electrical connections. Aluminum busbars, thanks to their excellent electrical conductivity and lightweight characteristics, have become key connecting components inside the modules. Laser welding technology, with its advantages of high energy density and precise heat input, effectively resolves process challenges such as oxidation and incomplete welding during the welding of aluminum busbars and cell tabs.

In the welding quality control system, metallographic inspection plays a critical role. By analyzing the microstructure of weld seams, it can accurately evaluate weld penetration depth, grain morphology, and defect distribution. This micro-level quality verification ensures the low-resistance performance and mechanical strength of the aluminum busbar connection interface, providing important support for enhancing the overall conductivity, cycle life, and safety reliability of battery modules. It has thus become an indispensable quality control step in the manufacturing process of power battery systems.

Macro Metallographic Sample Preparation Scheme for Laser-Welded Aluminum Busbars:

1️⃣ Rough Grinding: P1200 sandpaper with wax coated on the surface

2️⃣ Rough Polishing: GF + 9μm PD-WT polycrystalline diamond

3️⃣ Intermediate Polishing: YS-JP + 3μm PD-WT polycrystalline diamond

4️⃣ Fine Polishing: ZN-JP + 50nm SO-T401 silicon dioxide

5️⃣ Etching: Koll’s reagent

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