Zia Uddin, Erica Liverani, Alessandro Ascari, Alessandro Fortunato
The increasing demand for reliable and high-performance electric vehicle (EV) batteries requires precise and defect-free welding of battery components. Conventional Gaussian laser beam welding faces challenges such as keyhole instability, spattering, porosity, and brittle intermetallic compound formation, particularly in dissimilar Al-Cu joints. These issues significantly affect the electromechanical performance and durability of battery connections. Beam shaping technology has emerged as a core method for improving weld quality, process stability, and efficiency in laser welding, making laser beam welding increasingly vital for high-volume production of e-mobility components. This review systematically evaluates recent advancements in laser beam shaping for laser welding, especially static beam configurations, such as core-ring profiles, flat top, elliptical, and shaped beams; emphasis has been placed on how altering the intensity distribution influences the challenges associated with conventional welding and emerges as an effective solution to address these challenges. By tailoring the spatial energy distribution, beam shaping improves control of heat input, stabilizes melt pool dynamics, and enhances microstructural uniformity. Static beam shaping, compatible with cost-effective near-infrared continuous-wave laser systems, is already being adopted in industry, whereas dynamic beam shaping remains at an earlier stage of industrial maturity. This review highlights key welding challenges in EV battery manufacturing, evaluates beam shaping strategies as practical solutions, and identifies future research directions for large-scale industrial implementation.