Working with thick welded aluminum busbars?

thoroughbred

100 W
Joined
Apr 11, 2018
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225
Location
virginia
I'm working with some ev prismatic cells joined with busbars. It looks like there is a thick pad used for each terminal upon which a busbar is attached by laser welding.

I don't have a mill so my first attempt to separate cells was by drilling around the circular welded area. The hole saw i tried was too aggressive. Any other techniques I should consider?

This way works but it's ugly20200710_171759.jpg
 
A Dremel tool with a diamond cutting wheel might work. However, be sure not to short anything with the sparks and flying metal particles.

:D :bolt:
 
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