Application and development of aluminum for new energy vehicles – battery aluminum tray

Aluminum alloys are widely used in new energy vehicles. Aluminum alloys can be used in structural parts and components such as bodies, engines, wheels, etc. Against the background of energy conservation and environmental protection needs and the advancement of aluminum alloy technology, the amount of aluminum alloys used in automobiles is increasing year by year. According to relevant data, the average aluminum use in European cars has tripled since 1990, from 50KG to the current 151KG, and will increase to 196KG in 2025.

Different from traditional cars, new energy vehicles use batteries as power to drive the car. The battery tray is the battery cell, and the module is fixed on the metal shell in a way that is most conducive to thermal management, playing a key role in protecting the normal and safe operation of the battery. Weight also directly affects the vehicle load distribution and endurance of electric vehicles.
Aluminum alloys for automobiles mainly include 5××× series (Al-Mg series), 6××× series (Al-Mg-Si series), etc. It is understood that battery aluminum trays mainly use 3××× and 6××× series aluminum alloys.
Several commonly used structural types of battery aluminum trays
For battery aluminum trays, due to their light weight and low melting point, there are generally several forms: die-cast aluminum trays, extruded aluminum alloy frames, aluminum plate splicing and welding trays (shells), and molded upper covers.
1. Die-cast aluminum tray
More structural characteristics are formed by one-time die-casting, which reduces material burns and strength problems caused by welding of the pallet structure, and the overall strength characteristics are better. The structure of the pallet and frame structure features are not obvious, but the overall strength can meet the battery holding requirements.
2. Extruded aluminum tailor-welded frame structure.
This structure is more common. It is also a more flexible structure. Through the welding and processing of different aluminum plates, the needs of various energy sizes can be met. At the same time, the design is easy to modify and the materials used are easy to adjust.
3. Frame structure is a structural form of pallet.
The frame structure is more conducive to lightweighting and ensuring the strength of different structures.
The structural form of the battery aluminum tray also follows the design form of the frame structure: the outer frame mainly completes the load-bearing function of the entire battery system; the inner frame mainly completes the load-bearing function of modules, water-cooling plates and other sub-modules; the middle protective surface of the inner and outer frames mainly completes the gravel Impact, waterproof, thermal insulation, etc. to isolate and protect the battery pack from the outside world.
As an important material for new energy vehicles, aluminum must be based on the global market and pay attention to its sustainable development in the long term. As the market share of new energy vehicles increases, the aluminum used in new energy vehicles will grow by 49% in the next five years.