Aluminium Extrusions – The Preferred Choice For Battery Enclosures In EVs

The last two years have seen tremendous growth in the passenger vehicle segment in electric vehicles with sustained interest in the two and three wheeler market as well. Global awareness of depleting fossil fuels and eagerness in seeking alternatives has given the impetus towards Electric Vehicles. Electric cars are expected to ac for more than 30% of the total market share in 2030.

One of the most popular uses of extruded aluminum now is as the battery enclosure for Electric Vehicles. As the name indicates a battery enclosure is an enclosure to hold the battery modules and to protect them damage due to temperature variations and shocks. Aluminium with its lighter weight helps with complex and customized formability essential for deep draws of vehicle battery pack design and in reducing the overall vehicle weight which has a direct impact on the energy consumption. 

An ideal battery enclosure that uses aluminium extrusions can significantly simplify the assembly process and fixation of battery modules. When the complete battery enclosure is made of extruded aluminium, it helps in creating a natural electromagnetic shield that prevents interference with other electronic components in the vehicle. Aluminium extrusions also allow better energy absorption in case of an accident, compared to steel or carbon fibre.

PROPERTIES THAT MAKE ALUMINIUM A PREFERRED OPTION FOR BATTERY ENCLOSURES

LIGHTNESS

A battery enclosure made of extruded aluminium can be 50% lighter than one made of steel. It will be a very energy efficient option for original equipment manufacturers and battery pack manufacturers. This will afford more space for vehicles with large power packs too.

THERMAL CONDUCTION

The battery enclosure should have ideal thermal conductivity. They must help in keeping batteries cool in hot weather and warm in cold weather. The thermal transference capabilities of the enclosure can have a significant bearing on the life of battery modules. Battery performance also varies with the quality of aluminium used.

STRENGTH AND RESISTANCE TO IMPACT

The batteries need to be protected vagaries of weather, road debris, stone impacts or possible vehicle crashes. So it is important that a high strength material like aluminum is used for holding the batteries. The corrosion resistance it has also makes aluminum a safe bet.

When we multiply the projected sales number of Electric Vehicles with an average 80 kilograms of extruded aluminium used per vehicle, the requirement globally is estimated to exceed three million tons of extruded aluminium by 2040. Supplies top of the line aluminum extrusion manufacturers are hence imperative to ensure high performance and match the quality standards.

Some of the world’s leading EV manufacturers like Nissan, Volkswagen and Tesla are also moving to aluminium instead of steel which they are used to traditionally for making their battery enclosures. The possibility of an easier end-of-life recycling, anti corrosive properties and durability makes aluminium a much more cost effective choice as well.

Source: https://kmcaluminium.com/aluminium-extrusions-the-preferred-choice-for-battery-enclosures-in-evs/