Hybrid use of a robotic welding system in remote laser separation of thin-sheet Al casings for the recycling of battery packs

Robotic systems equipped with high-power laser sources are often employed for the production of battery packs for the electric mobility sector. Considering the strive toward a circular manufacturing economy, there is great interest in the possibility of reconfiguring such equipment for dismantling operations. The present study explores the hybrid use of a robotized fiber laser welding system, adapting its scope from joining of battery casings toward the separation of the same thin Al sheets, enabling the recycling of the internal cells of the battery pack. Process feasibility is assessed by tailoring the beam size as well as exploiting dynamic beam oscillation to perform the separation process. Dynamic beam oscillation allows us to obtain a smaller kerf width and greater process stability with respect to linear trajectories with larger beam sizes. The damage to underlying cells of the separation region was also assessed on different materials (Al, Ni-plated steel, and Cu). Greater surface modifications and higher peak temperatures (in excess of 800 °C) were recorded when employing dynamic beam oscillation with respect to linear trajectories. This research demonstrates a pathway for reutilization of the existing technological systems for a circular and sustainable production chain in the e-mobility sector.