Adhesive coating and coating pretreatment for electric vehicles

Aluminum anti-corrosion

Laser replaces chemical processes to achieve higher sustainability

TRUMPF has developed laser application technology for battery coating and pre-treatment, as well as anti-corrosion of aluminum components, aimed at improving the safety of electric vehicle batteries and enhancing the overall rust prevention performance of the vehicle.

Selective laser surface treatment is a clean and high-speed alternative solution for the automotive industry, which can significantly improve the adhesion of adhesives or coatings.

—— Volkan Yavuz， Head of Surface Treatment Business at Tongkuai Laser

At the Parts2clean exhibition in Stuttgart, Tongkuai showcased its comprehensive surface treatment manufacturing solutions, including TruPulse 5050 nano short pulse laser, PFO33 scanning optical lens, and samples for coating pre-treatment and anti-corrosion processes.

TruPulse 5050 Nano Short Pulse Laser

Laser technology safeguards the safety of electric vehicle batteries

Before assembling battery cells into modules or trays, manufacturers need to apply coating or film coating to them. This coating can effectively prevent short circuits and environmental erosion, thereby improving the safety and service life of the battery. Before implementing coatings and adhesives, manufacturers will use short pulse lasers to clean specific areas of the battery cells and trays. Short pulses act on the surface of the material without damaging the substrate.

Our laser technology can reliably remove oil stains, rust, oxides, and other residues without the need for powerful chemicals or mechanical polishing, achieving long-term stable adhesion between coatings and adhesives.

—— Volkan Yavuz， Head of Surface Treatment Business at Tongkuai Laser

In addition, the laser system can be easily integrated into automated production lines.

Laser rust prevention for aluminum parts

The automotive industry is increasingly using large aluminum castings (known as "integrated die casting" in the industry) in body manufacturing. During the casting process, a corrosion-resistant layer is formed on the surface of the component, but subsequent milling and other processing can damage this protective layer, especially in the winter road salt environment, which can easily cause corrosion. To address this challenge, Tongkuai has developed a corresponding solution: laser can selectively remelt the surface layer to a depth of micrometers, and achieve surface homogenization through rapid quenching, thereby restoring the corrosion resistance of aluminum components. In the salt spray test, the laser treated components showed no signs of crevice corrosion after being continuously sprayed with salt water for several hours.

This technology is not a future concept and is currently widely used in fields such as integrated die-casting components and electric vehicle drive motor housings.

—— Volkan Yavuz， Head of Surface Treatment Business at Tongkuai Laser

To handle large surface area workpieces such as large aluminum components, users can use the TruMicro 7000 series pulse laser with a PFO33 scanning optical lens. The reflector of PFO33 can scan laser pulses onto the surface of the workpiece at a speed of several meters per second, achieving short cycles and meeting the mass production needs of the automotive industry. The smoke, particles, and aerosols generated during processing are immediately expelled by a local suction system to avoid interference with the processing.

PFO33 scanning optical lens

Sustainable surface treatment

Compared to traditional processes, laser surface treatment has significant environmental advantages: it does not require the use of chemicals, reducing the impact on the environment and disposal costs; Non contact machining reduces tool wear and material waste; Meanwhile, efficient and precise laser processing helps reduce carbon emissions during the manufacturing process.