Welding is a critical process for many industries. But its importance in the automotive industry is evident and undeniable. 

Welding is often used to maintain a vehicle’s structural integrity, introduce new safety measures, and protect occupants in the unfortunate case of a collision. More recently, it has found many applications in the manufacturing of electric vehicles.

What role does welding play in designing the vehicles of the future? Let’s dive in.

Welding in the Automotive Industry

In many ways, welding processes in the production of electric vehicles are similar to those used in making traditional vehicles.

Certain micro-welding processes are employed on crucial components like sensors, batteries, and electronics while traditional processes, like MIG and TIG welding, are used to make a vehicle’s frame more durable. 

Welding is also a critical process for making airbags and other safety measures. 

Welding for Electric Vehicles

Welding EVs comes with its own challenges. Fortunately, these can be successfully addressed with the right welding techniques and equipment.

Making Lightweight Vehicles 

Operational range is an important aspect of producing EVs. Manufacturers are constantly looking for ways to extend the range of electric vehicles so they can travel as far as possible on a single charge. To do this, they must find ways to make their vehicles lighter.

Friction welding comes in handy in this case as it allows welders to fuse dissimilar, more lightweight metals like copper and aluminum. This technique doesn’t rely on fillers or flux which add more weight to a specific part.

Improving Battery Performance 

One of the most critical uses of welding in EV manufacturing is enhancing the performance of its battery.

The average EV battery pack is made of an intricate network of cells. A Tesla’s battery pack, for example, has up to 7,000 cells. Failure in any of these cells can cause a malfunction, making welded joints crucial in ensuring the safety and durability of an EV. 

Laser welding is the most widely used technique in EV batteries as it creates fast and precise joints. Laser welding’s benefits include its low thermal energy input. Additionally, it’s a green technology which is in line with many companies’ sustainability goals.

Making Watertight Welds

Friction stir welding is used to create tight seals that don’t allow liquid to seep through. Since EVs are comprised of several delicate electric components, it’s an important feature for welds.

Dealing with High Voltage 

To shorten charging times, EVs run on a much higher voltage than regular vehicles. At the same time, manufacturers must fuse together special high-voltage cables, a task that requires specialized expertise in certain processes like ultrasonic cable welding. Successfully performing this activity minimizes the EV’s loss of power.

Apart from these processes, welding is also used to manufacture battery trays, fuel tanks, mounting brackets, heat exchangers, and so much more!

Forge Forward with nexAir’s KnowHow 

Undeniably, the production of EVs will radically grow in the next few years. As one of the leading suppliers of welding equipment across the Southeast, nexAir is proud to say that it is making EV innovations and manufacturing possible.

For over 80 years, we’ve remained updated on the latest technologies, ensuring all our customers in the automotive industry Forge Forward with the latest KnowHow. 

Contact our experts for more information about our state-of-the-art welding equipment and welding best practices.