WELDING SYSTEMS AND METHODS WITH KNURLED WELD INTERFACES FOR METALLIC WORKPIECES

Presented are metalworking systems for joining metallic workpieces, methods for forming and welding such workpieces, and lithium-ion battery pouch cells with anodized aluminum tabs joined via knurling and laser welding. A method for laser welding abutting sections of a workpiece or stackup of workpieces includes receiving, via a workpiece support frame, one or more metallic workpieces each with a surface having applied thereto a treatment layer. This treatment layer releases a gas during welding. A metalworking device forms a knurl pattern into the workpiece surface with the treatment layer. The knurl pattern includes a network of channels, such as one or more series of mutually parallel, rectilinear vent channels, designed to exhaust therethrough the gas released from a welded section of the treatment layer. A laser welding device thereafter welds a joint region of the surface(s) of the one or more metallic workpiece with the knurl pattern.