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Battery Terminal Weld Pull‑Test Fixtures

Busbar Weld Shear Tensile Test Machine, Battery Terminal Weld Pull‑Test Fixtures

ISO 4136

UnitedTest supplies busbar welding shear tensile test equipment and custom weld pull‑test fixtures for battery terminal weld strength verification. Test busbar laser weld, ultrasonic weld spot joint, measure shear force, tensile breaking load for EV battery, energy storage cell busbar connection quality validation. 


Busbar welding test (battery busbar welding shear test, battery terminal weld tensile pull test) is a critical mechanical quality validation for lithium‑ion battery packs, energy storage modules, EV power battery assemblies. It evaluates the mechanical integrity of welded joints between copper‑aluminum busbars, cell tabs, battery terminals, collecting bars, busbar‑tab laser welds and ultrasonic spot welds.

General introduction

UnitedTest supplies busbar welding shear tensile test equipment and custom weld pull‑test fixtures for battery terminal weld strength verification. Test busbar laser weld, ultrasonic weld spot joint, measure shear force, tensile breaking load for EV battery, energy storage cell busbar connection quality validation.


Busbar welding test (battery busbar welding shear test, battery terminal weld tensile pull test) is a critical mechanical quality validation for lithium‑ion battery packs, energy storage modules, EV power battery assemblies. It evaluates the mechanical integrity of welded joints between copper‑aluminum busbars, cell tabs, battery terminals, collecting bars, busbar‑tab laser welds and ultrasonic spot welds.


Core Test Types

1. Busbar Weld Shear Test

Shear test applies parallel sliding force along the weld interface. The fixture fixes one side of the busbar assembly, while the test machine exerts shear load on the welded counterpart until weld spot separation. It records maximum shear force, shear failure load, failure mode: weld nugget pull‑out, interface delamination, base material tearing. Widely used for ultrasonic spot weld, laser welded busbar‑tab joints.

2. Battery Terminal Weld Tensile / Pull‑off Test

Tensile pull test pulls vertically perpendicular to the weld plane. The upper fixture clamps the terminal / tab, lower fixture securely holds the busbar substrate. The universal tester pulls at constant test speed, captures peak tensile force, displacement‑force curve. This test checks pull‑off strength of battery terminal welding, busbar‑terminal welded connection, to avoid joint detachment under vibration and mechanical shock in battery service life.

Key Features

  • Battery Terminal Weld Tensile Test
  • Battery Busbar Welding Shear Tensile Test
  • Key Features
  • Application Field
  • Keywords
  • Related Test Fixtures for Battery Welding Tests

Purpose: To verify the tensile/pull-off strength of battery tabs, terminals, and current collectors.

Test Method: The battery terminal or tab is securely clamped. Custom insulated wedge grips or flat-jaw grips are used to hold the busbar/tab without slipping or damaging the thin foil. A vertical tensile force is applied.

Key Parameters: Crosshead speed is often set between 5~50 mm/min. The system records the real-time force-displacement curve.


Purpose: To evaluate the shear strength and interface bonding quality of welded busbars (copper/aluminum busbars) and terminal connections. This prevents virtual welding (false welding) that could lead to high internal resistance or detachment.

Test Method: Specimens are prepared as standard lap joints. They are mounted into a dedicated lap shear fixture. The universal testing machine applies a constant tensile load until the weld fractures.

Key Parameters: Test speeds typically range from 5 to 10 mm/min. Peak load, fracture displacement, and failure modes (e.g., button pull-out, interfacial tearing, base metal rupture) are recorded.


UnitedTest is a professional manufacturer of busbar welding shear tensile test machines and custom weld test fixtures. Our universal material testers together with dedicated busbar test fixtures complete full battery weld mechanical assessment: busbar shear strength test, battery terminal weld pull test, busbar‑tab joint tensile test, copper‑aluminum dissimilar weld mechanical evaluation. Our test system exports complete test reports, force‑displacement curves, supports lab data archiving for battery R&D and QC departments.

EV lithium battery module production, 

energy storage battery incoming quality inspection, 

busbar welding process development, 

welding parameter verification, batch production quality control, 

R&D lab material joint performance evaluation.

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UnitedTest provides a wide range of interchangeable, high-precision battery testing fixtures designed for safety and accuracy:


Lap Shear Fixtures: Ensure the specimen axis aligns perfectly with the loading direction to avoid eccentric torsion.

Busbar / Tab Tensile Fixtures: Designed with anti-slip teeth or flat jaws to prevent slipping during the pull-off test.

Insulated Battery Grippers: Made of insulating materials (like PA6) or aluminum alloy (AL6061) with black anodizing/sandblasting. They prevent short circuits and fit cylindrical battery cells (e.g., 12mm-50mm diameter) securely.

Quick-Change Modular Design: Standard interfaces allow for rapid fixture swapping to meet various testing needs.


Main Technical Specification

Test load range: 50N‑10kN, matching small cell tab weld up to heavy‑duty EV busbar


Test speed: 0.5‑500 mm/min adjustable, follow battery industry test specifications


Output data: maximum shear force, maximum tensile pull force, force‑displacement curve, breaking displacement, failure mode record


Test specimens: copper busbar, aluminum busbar, copper‑aluminum dissimilar metal welds, battery tabs, cell terminals, busbar‑tab laser weld samples, ultrasonic spot welded joints


Common failure modes: weld interface fracture, nugget tearing, base metal rupture, partial spot peeling

Standard

ISO 4136 Transverse Tensile Test for Welded Joints

ISO 4136 Destructive tests on welds in metallic materials — Transverse tensile test

ISO 4136 specifies the specimen dimensions, extraction, machining, and procedure for performing a transverse tensile test on a welded butt joint to determine: Tensile strength (Rm) of the welded joint, Location of fracture (weld metal, heat-affected zone, parent metal, etc.), Basic fracture-surface observation. It applies to metallic materials in any product form joined by any welded butt joint process.


ISO 14273 Tensile Shear Test for Resistance Spot and Embossed Projection Welds

ISO 14273 Resistance welding — Destructive testing of welds — Specimen dimensions and procedure for tensile shear testing resistance spot and embossed projection welds.

ISO 14273 defines how to prepare, grip, load, and report the destructive lap-joint tensile shear test used to measure the maximum force a resistance spot weld or embossed projection weld can carry in shear.

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