Battery tab having a localized welded joint and method of making the same

A method for joining a plurality of metal work pieces, comprising the steps of:

• a. arranging a first work piece adjacent a second work piece such that a joining surface of the first work piece is facing toward a corresponding joining surface of the second work piece;
• b. providing a resistive coating on at least one of the joining surface of the first work piece and the joining surface of the second work piece;
• c. forming an assembly by compressing the first work piece and the second work piece together such that the resistive coating is sandwiched between the joining surface of the first work piece and the joining surface of the second work piece;
• and
• d. conducting an electric current through the assembly such that that resistive coating reacts with the electric current to generate sufficient heat to generate a bond joining the first work piece to the second work piece.

A battery pack assembly made by a process comprising the steps of:

• arranging a plurality of battery tabs into a stack assembly, wherein each of the battery tabs includes an exterior surface and an interior surface;
• providing a resistive coating on at least one of the interior surfaces and the exterior surfaces of the battery tabs;
• and
• resistive heating the stack assembly to a temperature sufficient for the resistive coating to form a bond between adjacent battery tabs, thus joining the plurality of battery tabs with a layer of resistive coating between adjacent battery tabs.