Enhancing Laser Cut Quality of Copper Thin Foils for Lithium-Ion Batteries through Pre-Cooling and Teaching–Learning–Based Optimization

The efficiency and performance of lithium-ion batteries are highly influenced by the quality of laser cutting of electrode materials. The laser cut quality of thin foils is often measured by amount of kerf width and heat-affected zone (HAZ). This article adopts a novel approach that involves pre-cooling of thin copper foils prior to the laser cutting process. The impact of laser conditions and foil temperature were analyzed on HAZ and kerf width induced during laser cutting experiments conducted based on L27 orthogonal array. Teaching–learning–based optimization (TLBO) technique was employed to identify the optimal laser parameters. ANOVA results indicated that the temperature was the most significant factor influencing kerf width and HAZ. The optimized laser parameters identified through TLBO technique were 16 W laser power, 69.47 mm/s scanning speed, and 20 kHz pulse frequency at dry ice conditions. A reduction of 50.76% kerf width and a decrease in 7.6% HAZ were observed when the foils were cut at dry ice conditions. The quality of cut surfaces were further examined using scanning electron microscope.