Tim Frech’s expertise is in the areas of microwelding, ultrasonic metal welding, ultrasonic soldering, wire bonding, and resistance welding. He is also experienced in plastics joining, laser welding, and helium leak detection. Tim helps clients select the proper welding process for the application and uses EWI’s laboratories to develop process parameters to ensure a robust welding operation. He has experience in welding of electronic modules, electric vehicle batteries, and medical devices.
Tim holds two U.S. patents in welding process technologies. He led EWI’s work on a Department of Energy-funded program entitled “Enabling the All-aluminum Vehicle,” and another program for development of joining methods for electric vehicle batteries.
Tim is also developing technologies for battery manufacturing and high-reliability electronics. A recent project involved development and deployment of a resistance welding process for replacement of solder joints on a satellite application.
Lithium-ion cells are commonly used in consumer electronics and electric vehicle applications and have an expanding presence in the aerospace industry. With increased demand for lithium-ion cells in recent years, EWI has experimented with many ways to optimize lithium-ion cell manufacturing. The most recent area of study has been the joining of tabs and busbars to the outer casing of the batteries. This presentation will describe the results of that study, and recommendations for joining several material combinations.