Joining by Forming of Hybrid Busbars for E-Mobility
Project name: Joining by Forming of Hybrid Busbars for E-Mobility
Project code: Busbars - PTDC/EME-EME/0949/2020
Project timeline: 2021 - 2024
Research group: Manufacturing and Industrial Management
This project was designed to provide the following contributions to science and technology of materials processing. Firstly, to provide new joining by forming processes to produce hybrid busbars for electric vehicles and for electric applications, in general. Secondly, to obtain a clear understanding of the deformation mechanics of the new processes and of their workability limits and typical failure modes, by means of a combined theoretical and experimental investigation that will make use of finite element modelling and experimentation in flexible tool systems, to be designed and fabricated by the authors. Thirdly, to investigate which materials (copper or copper-aluminium) should be employed for obtaining the best electric and formability performances at a lower cost, and to compare the electric contact resistance of the new hybrid busbars produced by joining by forming against those produced by fastening or welding. Fourthly, to determine the pull-out, shear and fatigue strength of the hybrid busbars produced by joining by forming and by conventional fastening or welding. Fifthly, to move towards industrialization by producing hybrid busbars in collaboration with a Portuguese SME that fabricates automotive components.