Are aluminum battery enclosures a good choice?

Aluminum battery enclosures or other platform parts typically provide a weight savings of 40% compared to an equivalent steel design. 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.

Are EV battery enclosures steel or mixed-material?

Some OEMs already have begun shifting to steel or mixed-material designs for their battery enclosures, Afseth acknowledged. Tesla is a prime example. The EV maker has reduced the amount of aluminum in the battery enclosure for the Model 3 and Model Y compared to what was used in its S and X models, according to Afseth.

What material is used for a battery enclosure?

The majority of long-range BEVs in production use aluminum as the main material for the battery enclosure. (Constellium) Mass reduction is the main driver behind aluminum battery enclosures, but thermal requirements prove challenging for the lightweight material.

How to choose the best aluminum battery housing material?

Choosing a high-quality aluminum battery housing material and selecting the optimal encapsulation process based on the characteristics of the case material is essential for ensuring the safety and service life of the battery. Currently, 3003 aluminum sheet is typically used for electric vehicle aluminum battery housings.

Are aluminum alloy sheets suitable for lithium-ion battery cases?

At HDM, we have developed aluminum alloy sheets that are perfect for cylindrical, prismatic, and pouch-shaped lithium-ion battery cases based on the current application of lithium-ion batteries in various fields. Our aluminum alloy materials are user-friendly, compatible with various deep-drawing processes.

Can aluminum battery enclosures be used for small cars?

(Constellium) Mass reduction is the main driver behind aluminum battery enclosures, but thermal requirements prove challenging for the lightweight material. 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.”