Application of extruded aluminum in electric vehicles

Extruded aluminum plays a very important role in electric vehicles. First, the battery system must be made of lightweight materials, which is more important than in other cars; second, it is a strong competitor for manufacturing battery trays and cooling systems, and a good material for manufacturing motor housings.

Weight and stroke

The weight of an electric car limits its travel. According to estimates by Ducker Worldwide, Volkswagen’s e-Golf (which has been replaced by ID.4 cars) electric vehicle battery system weighs more than 227kg, which is heavier than the same type of internal combustion engine (ICE). The mass of batteries, motors, control systems, wires and cables of electric vehicles exceeds 454kg; the battery mass of TeslaS electric vehicles is 544kg, the motor capacity is 85kWh, accounting for 27% of the vehicle weight; the same is true of the CheryBolt electric vehicle, 66kWh, the battery mass is 436kg, accounting 26% of the car's weight.

Although the energy density of batteries continues to rise, car buyers' wishes are that the range can be increased significantly, and weight reduction is not a top priority. In short, due to the addition of advanced driver assistance systems (ADAS, advanced driverassistance systems) hardware, pre-alarm system, front collision warning/automatic braking system, the total mass of the car will increase by 136kg ~ 180kg.

The use of extruded aluminum parts and other aluminum workpieces is an effective measure to reduce the quality of the car. Extruded aluminum can be used for crossbodybeam/instrument panel, roof bow, underbody crossbeam, etc. Manufacturing, and using hollow thin-wall extruded complex aluminum profiles can further reduce the weight of parts. It is a strategic matter to use extruded aluminum to manufacture more and more electric vehicle parts. Aluminized, so-called all-aluminized is under the current technical conditions, on the premise of ensuring driving safety and comfortable seating, all parts that can be made of aluminum alloys and magnesium alloys are made of light metal materials.

According to data from the London Commodity Research Institute (CRU), the total global ABS (AutoBodysheet) consumption is about 1700kt in 2019, including 950kt in North America, 550kt in Europe, 90kt in China, and 110kt in other markets. According to the "Aluminum Quantity Assessment Report of China's Automobile Industry (2016~230)" by the International Aluminum Association in October 2019, the demand in 2030 is predicted to be 9100kt, with a compound annual growth rate of 8.9%. China's implementation of the "New Energy Vehicle Subsidy Exemption from Purchase Tax Policy for 2 Years" in 2020 will help reduce the pressure on the cost of the industrial chain, give companies with core technology and willing R&D investment more room for growth, and help expand aluminum materials. application. Not only will the amount of sheet metal used for cover parts increase significantly, but also the amount of outer panel products, battery baseboard products and power battery foil will increase simultaneously.

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