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Numerical simulation of resistance welding of solar cell using a thermal-electrical-mechanical coupled model

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Abstract

A thermal-electrical-mechanical coupled model was established to simulate the Parallel-gap resistance welding (PGRW) process between the Germanium-based solar cell and the silver interconnector. The simulated results showed that the peak temperature during PGRW is lower than the melting temperature of the base material. It is indicated that the connection mechanism of PGRW was mainly the interdiffusion and recrystallization due to pressure of electrode and the resistance heat. A detailed calculation method of current was proposed using semi-layered resistance model and layered resistance model. By comparing these models, it was found that the layered resistance model was more accurate to calculate the current value. The maximum residual stress was generated within the region under the welding electrode, while the maximum deformation was generated on the edge of the interconnector. The current variation trend predicated by the simulation results is in good agreement with the results obtained by the experiments.

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Authors and Affiliations

  1. Nanjing University of Aeronautics & Astronautics, Nanjing, 211100, China

    Xiaohong Zhan, Qi Zhang, Zhenxin Zhu & Yanhong Wei

Authors
  1. Xiaohong Zhan
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  2. Qi Zhang
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  3. Zhenxin Zhu
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  4. Yanhong Wei
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Correspondence to Xiaohong Zhan.

Additional information

Recommended by Associate Editor Young Whan Park

Xiaohong Zhan, who is born in 1979, is an Associate Professor in Nanjing University of Aeronautics and Astronautics, China. He mainly engages in welding process numerical simulation, laser welding and laser additive manufacturing, aerospace and other advanced manufacturing technology research work.

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Zhan, X., Zhang, Q., Zhu, Z. et al. Numerical simulation of resistance welding of solar cell using a thermal-electrical-mechanical coupled model. J Mech Sci Technol 32, 269–276 (2018). https://doi.org/10.1007/s12206-017-1227-5

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  • DOI: https://doi.org/10.1007/s12206-017-1227-5

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