Assessment of the technological potential and maturity of a novel joining technique based on reactive nanofoils

Manufacturing companies in the automotive industry are confronted with the rising demand for long-range electromobiles. The traction battery must be interconnected internally with low electrical resistance within the joints to achieve a high-performance powertrain. Joining based on reactive nanofoils represents an innovative manufacturing technology to meet the aforementioned demand. However, the integration of a new technology or the substitution of a well-established technology in a running production environment represents a strategic management decision associated with high risks. The awareness of the industry concerning the technological capability of reactive nanofoils is currently low, as this technology is classified as new and emerging. Therefore, this study addresses the assessment of the technological potential and the maturity of reactive nanofoils by presenting a use case, in particular the interconnection of a traction battery. The assessment was carried out for reactive nanofoils as well as for screwing, as the latter is ranked as the established technology in this matter. In the case of the former technology, the design of a state-of-the-art traction battery was adapted and manufactured.