“You can think of this high-modulus 4000 series alloy as a ‘very excess’ silicon 6000 series alloy,” Afseth said, noting that gauges and widths will be similar to 6000. A 40% weight reduction is “technically feasible” with the developmental 4xxx alloy. The current state-of-the-art solution for bottom plates is high-strength 6111 alloy in peak aged temper, which reduces weight by 30% compared to the benchmark 5754 O-temper alloy.Ĭonstellium has a 4xxx alloy in development with 80-GPa E-modulus and 350-MPa yield stress. The most-used and best-suited alloys for battery enclosures are of the 6000-series Al-Si-Mg-Cu family, Afseth shared, noting that these alloys are “very well compatible” with end-of-life recycling. “There will continue to be a very high value of lightweighting, so I would expect aluminum to be the material of choice.”Īluminum battery enclosures or other platform parts typically provide a weight savings of 40% compared to an equivalent steel design. “ Electric trucks will require very large batteries, maximum payload and minimum energy consumption (operating costs),” he said. Growth is driven in part by the increasing market share of BEVs, including electric trucks and vans, which already employ a greater amount of aluminum than do conventional-powertrain models – more than 640 lb (290 kg) in BEV platforms compared to about 450 lb (205 kg) in non-BEVs. “Aluminum continues to be the fastest-growing material in automotive application,” Afseth said. Andreas Afseth, technical director for Constellium North America operations, said during a recent Center for Automotive Research (CAR) webinar. All currently available long-range BEVs – those that can travel beyond 250 miles (400 km) – use aluminum as the main material for the battery enclosure for that very reason, Dr. Soon, it may no longer be economically beneficial to use aluminum, especially for the small cars that have moderate range and target the lowest possible price point.”Īluminum is the dominant material for electric vehicle (EV) battery enclosures for one simple but significant factor: lightweighting capability.
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