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RESIDUAL STRESS MEASUREMENT IN PLASTIC WELDED JOINS AND ITS APPLICATION TO THE DESIGN AND MANUFACTURE OF HYBRID ELECTRIC VEHICLE BATTERIES

Anantharaman, Satish

Abstract Details

2009, Master of Science, Ohio State University, Mechanical Engineering.
Hybrid electric vehicle (HEV) battery modules are designed for extended life (8-10 years) under real world environmental and driving conditions. The complex design and assembly of these battery modules coupled with aggressive chemicals in the electrolyte necessitate the use of plastics as enclosure material. Residual stresses resulting from plastic welding processes is a major cause for failure of a battery system. In order to minimize the effects of these residual stresses, it is important to undertake a systematic study to quantify and reduce them. Photoelasticity and solvent testing methods were used to experimentally determine residual stresses in hot plate and through transmission laser welded (TTLW) polycarbonate. The peak residual stresses measured by the two methods were in good agreement. Solvent testing technique was also used to successfully quantify the peak residual stress in vibration welded plastic assemblies used in HEV batteries. It was found that processes with shorter heating times and faster cooling rates, like vibration welding and TTLW, resulted in higher residual stresses. Annealing after welding could also be used to reduce the residual stress levels by as much as 40%. Hot plate welding has slower heating and cooling rates resulting in the lowest level of residual stresses and often eliminating the need for annealing. Minimization of the effects of residual stresses on battery performance and life through material and process selection and design modifications were also investigated.
Avraham Benatar, PhD (Advisor)
Blaine Lilly, PhD (Committee Member)
118 p.

Recommended Citations

Citations

  • Anantharaman, S. (2009). RESIDUAL STRESS MEASUREMENT IN PLASTIC WELDED JOINS AND ITS APPLICATION TO THE DESIGN AND MANUFACTURE OF HYBRID ELECTRIC VEHICLE BATTERIES [Master's thesis, Ohio State University]. OhioLINK Electronic Theses and Dissertations Center. http://rave.ohiolink.edu/etdc/view?acc_num=osu1250695031

    APA Style (7th edition)

  • Anantharaman, Satish. RESIDUAL STRESS MEASUREMENT IN PLASTIC WELDED JOINS AND ITS APPLICATION TO THE DESIGN AND MANUFACTURE OF HYBRID ELECTRIC VEHICLE BATTERIES. 2009. Ohio State University, Master's thesis. OhioLINK Electronic Theses and Dissertations Center, http://rave.ohiolink.edu/etdc/view?acc_num=osu1250695031.

    MLA Style (8th edition)

  • Anantharaman, Satish. "RESIDUAL STRESS MEASUREMENT IN PLASTIC WELDED JOINS AND ITS APPLICATION TO THE DESIGN AND MANUFACTURE OF HYBRID ELECTRIC VEHICLE BATTERIES." Master's thesis, Ohio State University, 2009. http://rave.ohiolink.edu/etdc/view?acc_num=osu1250695031

    Chicago Manual of Style (17th edition)