Current Status of Lightweight Aluminum Alloy Development for New Energy Vehicles

 

Technical approaches to lightweight of new energy vehicles

 

At present, there are three main technical approaches to lightweight new energy vehicles:
① Material lightweight, which involves the utilization of high-strength steel, aluminum alloys, magnesium alloys, titanium alloys, and composite materials.
② Structural lightweight, focusing on the optimization of size, shape, and topology.
③ Process lightweight, employing advanced manufacturing techniques such as hydraulic forming and laser welding processes.

 

Advantages of lightweight aluminum alloy materials for new energy vehicles

 

Among the various lightweight materials available, aluminum alloys stand out for their high strength compared to high-strength steel, significantly reducing vehicle body weight and offering excellent corrosion resistance. Their recycling process is straightforward, and they boast a high recycling rate, aligning with green environmental standards. Aluminum alloys are superior to magnesium alloys in terms of strength and ease of processing, and they are more cost-effective than titanium alloys, which are sensitive to processing parameters.

 

Compared to composites like plastics and carbon fibers, aluminum alloys are more suited for large-scale applications due to the latter's limited R&D and production capabilities. Consequently, aluminum alloys have emerged as the material of choice for lightweight new energy vehicles, ensuring quality, safety, and economy, while enhancing vehicle range.

 

 

Forming technology of aluminum alloy for new energy vehicles

 

The forming technology for aluminum alloys in new energy vehicles is primarily based on casting and semi-solid forming techniques. Additional methods include extrusion and forging. Casting is the most critical forming technology, encompassing pressure casting, extrusion casting, and precision casting. Die-casting forming technology yields aluminum products with a low scrap rate, high dimensional accuracy, and superior forming quality, making it the most widely used method. Semi-solid forming is a novel technique that takes advantage of the alloy's semi-solid state to achieve better filling and improved forming accuracy, though it is not yet mature enough for mass production.

 

Classification of aluminum alloys in lightweight new energy vehicles

 

Aluminum alloys used in new energy vehicles are categorized into cast aluminum alloys, deformed aluminum alloys, foamed aluminum materials, and aluminum-based composites. Cast aluminum alloys, stable in forming quality and suitable for mass production, are predominantly used in complex components like wheels and brake discs. Deformed aluminum alloys, with high strength and plasticity, are ideal for car doors, bumpers, and heat exchangers. Foamed aluminum, with its shock-absorbing and damping properties, enhances collision safety in supporting components. Aluminum-based composites, lighter and more wear-resistant, are suitable for harsh conditions, particularly in high-voltage battery systems.

 

 

New energy vehicles are mainly composed of three parts: an electric drive system, a power supply system, and an auxiliary system. Aluminum alloys have been widely used in the body, chassis, battery box, etc. of new energy vehicles.

 

Lightweight application of new energy vehicle body

 

The body of new energy vehicles constitutes a significant portion of the vehicle's weight. Aluminum alloy materials can significantly reduce body weight, thereby increasing the driving range. 6-series aluminum alloys, such as 6014 and 6016, are favored for their excellent formability and are commonly used in body exterior coverings. 5-series aluminum alloys, with superior forming performance, are ideal for complex parts and interior coverings, though they require careful control during the forming process to avoid lines.

 

Lightweight application of new energy vehicle chassis

 

The chassis of new energy vehicles, which supports the motor powertrain in place of the traditional engine, can incorporate aluminum alloys to replace TRIP steel materials, achieving a lighter design. Aluminum alloy castings like YL118, ZL119, and ZL120 are well-established in automotive chassis applications, enhancing the performance of components like brake discs and suspension systems.

 

Lightweight application of new energy vehicle battery tray

 

Battery trays, as a critical component of new energy vehicles, can benefit from aluminum alloy materials due to their low density, good heat dissipation, and stable chemical properties. The design of aluminum alloy profiles for the lower box of battery packs must consider lightweight, structural complexity, and the potential for diverse collision forms, ensuring the tray's stiffness and resistance to impact deformation. Leading manufacturers like Tesla, BYD, CATL, and Weilai have adopted aluminum battery trays, achieving a balance between lightweight design and structural integrity.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

From laser welding to hot stamping to integrated die-casting technology, the application of various new technologies not only improves production efficiency and product quality but also promotes the green transformation and sustainable development of the entire industry. If you are interested in aluminum alloy products, please click the link below.

 

https://www.stamping-welding.com/search/Aluminum.html