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Improvement Solutions for Poor Bonding & Delamination in Aluminum Flexible Connections Welded by Aluminum Diffusion Welders
Jul 02,2026
Widely used in new energy vehicle power batteries, energy storage power stations and electrical equipment, aluminum flexible connections feature light weight, excellent thermal & electrical conductivity and good flexibility, serving as core components for high-current flexible transmission. Most aluminum flexible connections are laminated by multiple thin aluminum foils. Welding quality determines product conductivity, mechanical reliability and service life. Aluminum diffusion welders have become mainstream equipment thanks to their solid-state atomic bonding, fusion-free process and low deformation.
I. Root Causes of Poor Bonding and Delamination
(1) Non-standard Pre-Treatment
1.Incomplete removal of aluminum oxide film: Simple wiping cannot break dense oxide layers, resulting in ineffective contact and weak bonding during welding.
2.Residual oil, dirt and unremoved oxide barriers block metallurgical fusion and increase delamination risks.
3.Unprocessed aluminum foil with surface contaminants, warped edges and loose lamination worsens delamination tendency.
4.Insufficient compression of multi-layer aluminum foils creates interlayer gaps and prevents effective metallurgical bonding.
(2) Improper Welding Parameters
1.Miscontrolled temperature: Excessively high or low temperature leads to loose bonding interfaces without stable fusion.
2.Unbalanced pressure fails to break oxide films and achieve full fusion, aggravating delamination.
3.Lack of staged heating triggers severe temperature fluctuations, reducing interlayer bonding strength and causing poor fusion.
(3) Abnormal Equipment Status
1.Insufficient temperature control accuracy creates large deviations between set and actual temperature, impairing fusion quality.
2.Stuck pressurization mechanisms, unstable pressure or worn graphite platens cause uneven heating and unbalanced stress distribution.
3.Poor equipment sealing allows air to enter welding zones, triggering aluminum foil oxidation and weak bonding.
(4) Improper Operation & Raw Material Control
1.Non-standard clamping leads to offset positioning or covered welding areas, lowering fusion performance.
2.Substandard aluminum flexible connection base material with internal impurities intensifies poor bonding.
3.Moving or forcibly handling uncooled workpieces after welding damages bonding surfaces and causes severe delamination.
II. Targeted Improvement Measures
1.Standardize pre-treatment: Clear all surface contaminants on aluminum flexible connections to eliminate fusion barriers and ensure tight lamination.
2.Precise positioning: Deploy dedicated positioning tooling to align aluminum flexible connections accurately and avoid offset.
3.Optimize welding parameters: Set temperature and pressure reasonably based on aluminum material characteristics to eliminate poor fusion caused by mismatched parameters.
4.Standardize equipment maintenance and operation: Calibrate equipment accuracy regularly to guarantee uniform pressure application, and fully inspect bonding quality after welding.
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Wuxi HAIFEI Intelligent Equipment Co., Ltd.
Wuxi HAIFEI Welding Equipment Co., Ltd.
Add: 28 Shuiyun Road, Yuecheng, Jiangyin, Jiangsu Province, China. (Postal Code: 214404)
Mobile: +86 18915302352
Email: wushijie@jshaifei.com