Previous Projects

Laser Welding

Integration of manual laser welder and Cobot

Integration of manual laser welder and Cobot for a large battery module with 7 material combinations across 430 locations. Delivered successfully in ~ 4 months from feasibility study, RFQ and PO, IQ, OQ, and PQ

Improving battery tab-to-cell laser weld acceptance rate and avoid rejects

Developed robust and consistent weld process and proper control

Resistance Welding

Resistance welding of large diameter round bar to thick flat sheet

Resistance welding of large diameter round bar (Ø19-25 mm) to thick flat sheet (2-3 mm). Redesigned parts and weld tool, developed robust weld process that could produce consistent acceptable welds

Ultrasonic Welding

Restore downed production due to changed material in ultrasonic metal welding process

Resumed production in ~ 5 weeks through weld tool redesign and new weld process redevelopment

UPH improvement of ultrasonic plastics welding

Achieved a 4,700% throughput increase (from ~ 8 minutes/unit to ~10 seconds/unit) through part redesign and automation implementation in production line

Patents & Publications

Patents

US-11,355,820 – Transferable Electrode Tip for Resistance Welding an Anode Tab To The Casing of An Electrochemical Cell (2022)
US-10,224,518 – Electrochemical Cell Casing Having an Open-Ended Main Body Portion of Grade 5 or 23 Titanium Closed by Upper and Lower Lids of Grade 1 or 2 Titanium (2019)
US-10,205,151 – Connector from The Tab of An Electrode Current Collector to the Terminal Pin of a Feedthrough in An Electrochemical Cell (2019)
US-10,118,245 – Sacrificial Resistance Weld Electrode (2018)
US-10,109,884 – Dual Weld Plug for An Electrochemical Cell (2018)
US-9,899,655 – Electrochemical Current Collector Screen Designs Utilizing Ultrasonic Welding (2018)
US-9,553,296 – Magnetic Pulse Welding in Medical Power Manufacturing (2017)
US-9,300,007 – Ultrasonic Welding-Pressing Lithium onto A Current Collector (2016)
US-9,061,400 – Magnetic Fixture (2015)
US-8,722,238 – Direct Resistance Welding-Self Brazing of Aluminum to Molybdenum Pin (2014)

Publications

X.Y. Dai, P.J. Bates – Mechanical Properties of Vibration Welded Short- and Long-Glass-Fiber-Reinforced Polypropylene, Composites Part A: Applied Science and Manufacturing, Vol. 39, Issue 7, July 2008.
C-Y. Wu, P.J. Bates, S.X.Y. Dai – Effect of Orientation on Vibration Weld Strength of TPO, SPE Automotive Thermoplastic Polyolefin Global Conference 2005.
X.Y. Dai, P.J. Bates, Vibration Welding Short- and Long-Glass-Fiber Reinforced Polypropylene Compounds, SPE Annual Technical Conference 2005.
X.Y. Dai, P.J. Bates – Mechanical Properties of Short- and Long-Glass-Fiber-Reinforced Polypropylene Compounds, SPE Annual Technical Conference 2005.
P.J. Bates, X.Y. Dai, C-Y. Wu – Vibration Welding Non-Planar Surfaces, SPE Annual Technical Conference 2005.
X.Y. Dai, G. Park, M. Kontopoulou, P.J. Bates – Force Measurement During Vibration Welding of Nylon 66, SPE 2004.
X.Y. Dai, Z.H. Wang – Developing Induction Hardened Wear-Resistant Pipe through Computer Simulation, Electric Power Construction (China), 1997.
X.Y. Dai – Failure Analysis of Burst Blade Wheel of Steam Turbine from Power Station, Water Conservancy & Electric Power Machinery (China), 1994.

Professional History

Yazaki North America
Principal Engineer – Welding and joining (Contract) · Canton, MI, USA
Milwaukee Tool
Senior Principle Advanced Manufacturing Technology Engineer · Milwaukee, WI, USA
Form Energy
Staff Process Engineer - Laser Welding · Weirton, WV, USA
Proterra
Staff Weld Process Engineer · Burlingame, CA, USA
XALT Energy
Senior Technical Specialist – Welding Technology · MI, USA
Integer Holdings (Greatbatch Medical, Inc.)
Senior Weld Engineer · NY, USA
Lear Canada - Kitchener plant
Weld Engineer · ON, Canada
Center for Automotive Materials and Manufacturing (CAMM), Queen’s University
Research Assistant – Joining Technology · ON, Canada
Foster Wheeler Energy Inc. (US)
Residence QA/QC Inspector · China
Electric Power Construction Research Institute
Material and Weld Engineer · Beijing, China
Erection Site of Daya Bay Nuclear Power Station
Weld Engineer · Guangdong, China

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