Aluminium Alloys in Electric Vehicles

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In the automotive industry today, traditional New Energy/Electric Vehicle (NEV/EV) battery packs usually use steel-framed structures to fulfil different safety regulations set by both the industry and the government. These structures ensure puncture resistance, explosion prevention, and the ability to bear loads as required.


The steel frame does a great job meeting safety demand, but it does pose an efficiency challenge for NEVs/EVs. Its substantial weight increases the overall vehicle weight, leading to higher rolling resistance. This resistance demands more energy to accelerate the vehicle and sustain a constant speed during cruising. As a result, it impacts the vehicle’s overall efficiency

Alloy Composition

Researchers are actively seeking methods to boost NEV/EV efficiency by cutting down the battery pack’s weight. One avenue they’re exploring involves using innovative lightweight aluminium alloy enclosures for battery packs, formed using high-pressure die-casting techniques. This approach aims to reduce the overall weight of the battery pack, thereby improving the vehicle’s efficiency.

EN AC-43500, also known as AlSi10MnMg, stands out as the primary aluminium alloy utilized for crafting structural components within the automotive chassis. Its application extends to various critical parts such as the oil pan, sunroof, convertible roof subassemblies, front axles, engine mounts, suspension mount assemblies, and multi-component subframes. This alloy’s versatility and high mechanical performance make it an ideal choice for these specific components, ensuring they meet the stringent requirements of the automotive industry in terms of strength, durability, and reliability. The following table compares the physical properties of AlSi10MnMg and other aluminium alloy materials.

The EN AC-43500 AlSi10MnMg die-cast alloy represents a significant advancement in achieving enhanced properties compared to standard die-cast alloys. In its as-cast condition, it typically offers a strain n value of 5-10%, which is already favourable for many applications.


However, through specific heat treatment processes, this alloy can achieve even greater elongation, surpassing 15%. Alternatively, the alloy can be tailored to reach a yield strength of 260 MPa while maintaining this increased elongation. This dual capability offers versatility: the alloy can either achieve higher ductility or a moderate strength level depending on the desired application or specific requirements within the automotive industry.


The EN AC-43500 AlSi10MnMg alloy offers a spectrum of favourable characteristics specifically tailored for die casting applications:

1. Excellent Casting Performance: This alloy exhibits remarkable casting performance, allowing for precise and intricate shapes during the die casting process. Its fluidity and fill characteristics make it ideal for intricate Mold designs.

2. No Adhesion on Die-Casting Molds: The alloy’s composition minimizes adhesion to die-casting Molds, facilitating smoother production processes and reducing potential issues related to Mold sticking or residue buildup.

3. Good Corrosion Resistance: Its resistance to corrosion ensures durability and longevity, essential qualities for automotive components exposed to various environmental conditions.

4. High Durability: The alloy’s robustness and resistance to wear make it suitable for demanding applications within the automotive industry, contributing to the longevity of parts and assemblies.

5. Good Welding Performance: Its weldability allows for ease in joining components, supporting efficient assembly processes in manufacturing.

6. Suitable for Punching and Pressing: Its characteristics enable it to withstand punching and pressing processes, further expanding its versatility in manufacturing operations.

These combined attributes make the EN AC-43500 AlSi10MnMg alloy a highly desirable material for die casting applications in the automotive sector, providing a balance of performance, ease of manufacturing, and durability.

With different heat treatment processes (see table below), the mechanical properties of the alloy can be adjusted.

 

Absolutely, combining the distinctive qualities of the EN AC-43500 alloy with cutting-edge die-casting techniques represents a strategic pinnacle in manufacturing innovation. This integration seeks to harness the inherent strengths of the alloy while capitalizing on advancements in die-casting methodologies.

The fusion of this specific alloy with sophisticated die-casting methods offers a pathway to streamline the manufacturing process. This union is expected to significantly enhance the overall quality, performance, and efficiency of automotive components. The alloy’s unique properties, such as high strength, improved
elongation rates, and suitability for heat treatment, synergize with the precision and capabilities of advanced die-casting techniques.


The result? Optimized production processes that yield components with superior structural integrity, durability, and dimensional accuracy. This approach not only enhances the quality of automotive parts but also contributes to increased efficiency in manufacturing, potentially reducing production costs and lead times while ensuring the components meet or exceed stringent industry standards.


Ultimately, this strategic amalgamation positions the alloy and die-casting techniques as a formidable combination, poised to elevate the standards and capabilities of manufacturing automotive components, particularly those vital for the evolving landscape of electric vehicles.


The engineering team’s exhaustive pursuit of meeting stringent heat treatment conditions for the castings led to extensive testing of various die casting methods. After rigorous experimentation, they pinpointed the vacuum die casting process as the most optimal method due to its exceptional compatibility with the specific requirements of heat treatment.


This process’s superiority lies in its ability to create castings that maintain structural integrity and exhibit minimal porosity, crucial factors for subsequent heat treatment. The vacuum die casting method ensures a controlled environment during casting, reducing air entrapment and gas porosity in the final product.


By selecting vacuum die casting, the engineering team has secured a method that aligns precisely with the stringent conditions necessary for the prescribed heat treatment. This precision and control over the casting process guarantee that the resulting components meet the exacting standards required ,enhancing their quality and suitability for subsequent heat treatment stages.

Absolutely, the use of vacuum die casting indeed leads to castings of exceptional compactness, meeting the stringent requirements posed by T4-T7 heat treatment conditions. This precision casting method enables meticulous control over the integrity of the castings, effectively reducing porosity and ensuring the alloy’s readiness for subsequent heat treatment stages.


By employing vacuum die casting, the engineering team attains castings with the crucial structural integrity and density needed for demanding applications. This meticulous approach guarantees that the resulting components meet precise specifications necessary for subsequent heat treatment processes. The
high level of control and minimized porosity achieved through this method contribute significantly to enhancing the overall quality and performance of the final automotive parts.


The ability to produce castings with such precision and integrity not only ensures compliance with strict heat treatment requirements but also lays the foundation for components that exhibit superior strength, durability, and reliability—essential attributes for critical automotive applications, especially in NEV/EV lightweight battery pack enclosures.

Achieving an elongation rate of 15-20% post-heat treatment signifies a remarkable advancement for the EN AC-43500 AlSi10MnMg alloy. This notable increase, surpassing typical aluminium alloy materials by 30 to 60 times in elongation, holds significant implications.

These exceptional elongation rates are pivotal in meeting the rigorous standards for fabricating high strength, durable structural components. Specifically, they prove instrumental in crafting lightweight battery pack enclosures for NEV/EV applications. The alloy’s capability to undergo heat treatment and attain such
elongation values ensures that the resulting components possess the requisite strength and resilience crucial for battery pack enclosures in electric vehicles.


This amalgamation of strength and elongation not only meets but exceeds the demanding criteria for structural components in NEV/EV applications. It allows for the creation of robust yet lightweight enclosures, aligning perfectly with the industry’s pursuit of efficient and durable solutions for electric vehicle battery packs.


The substantial improvement in elongation rates positions the EN AC-43500 AlSi10MnMg alloy as a highly promising solution for fabricating essential structural components in NEV/EV battery enclosures. This enhancement underscores its capacity to meet the automotive industry’s stringent demands for materials that are not only lightweight but also robust and resilient.

When comparing EN AC-43500 aluminium in its as-fabricated state to Euronorm (EN) cast aluminium’s, all aluminium alloys, or an entire database of alloys, the graphs might illustrate various material properties. These properties could include:

1. Tensile Strength: This measures the maximum stress a material can withstand while being stretched or pulled. EN AC-43500 might showcase its tensile strength in comparison to other alloys.

2. Yield Strength: The amount of stress a material can withstand without permanent deformation or yield. Comparisons might highlight this aspect to show its relative strength.

3. Elongation: This measures the amount a material can stretch without breaking during tensile testing, indicating its ductility.

4. Hardness: The resistance of a material to localized deformation. EN AC-43500 might be depicted in comparison to other alloys in terms of its hardness.

5. Density: The comparison of densities provides insights into the weight of the material, influencing its application in lightweight designs.

6. Modulus of Elasticity: This indicates the material’s stiffness or its ability to deform when subjected to an external force.

The bars on these graphs, as described, would represent the relative position of EN AC-43500 with respect to other alloys in each of these properties. A full bar signifies it has the highest value in that specific set, while lesser bars indicate it is comparatively lower in that property compared to the other alloys or the entire database.

These comparative graphs serve as visual aids to quickly assess how EN AC-43500 performs against other aluminum alloys across various critical material properties.

The alloy’s ability to deliver higher elongation rates, coupled with its inherent strength and suitability for heat treatment, fulfils the critical requirements for structural integrity in battery enclosures. This combination of attributes addresses the unique needs of the electric vehicle sector, where materials must exhibit both durability and lightweight characteristics.


By showcasing a balance between strength and elongation, the EN AC-43500 AlSi10MnMg alloy emerges as a frontrunner in fulfilling the rigorous demands of NEV/EV applications. Its potential to contribute to the creation of sturdy yet lightweight battery enclosures position it as a valuable material within the evolving landscape of electric vehicle technology.

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