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Battery tray lightweight, choose aluminum or high-strength steel?

September 7, 2019

With the rapid development of economy, the car has become a good partner for our travel. New energy vehicles have also become an inevitable trend of development, when it comes to new energy vehicles, Yuefeng aluminum technology has to lead everyone to look at, new energy vehicles battery trays, what secrets in it?


New energy vehicle power battery, due to its own weight defects and energy density demand contradictions, in the vehicle parts sub-system, the need for lightweight is particularly urgent. In the power battery, the tray accounts for 20 to 30% of the weight of the battery system, which is the main structural part. Therefore, under the premise of ensuring the safety of battery function, the lightweighting of the tray becomes one of the main improvement targets of battery structure.


From the material aspect, aluminum alloy material, first of all, can meet the structural needs of vehicle components, including battery system, is still the preferred material to replace some steel structure. However, the high-strength steel plate itself is also taking the path of lightweight technology. Therefore, aluminum alloy material and lightweight high-strength steel plate in the selection of materials on the road has been showing an alternating state of forward.

Alternately moving aluminum and steel

With the development trend of energy saving and environmental protection, aluminum is generally the main solution for enterprises to achieve lightweight, and its price is higher, but its excellent processing, low density (aluminum alloy density of 2.7g/cm), corrosion resistance, high recycling and other characteristics, the advantages are obvious, It is still an important symbol of the lightweight process of new energy vehicles that are electric.


Duck Global Consulting conducted research and forecasts on the average aluminum use of vehicles in North America, and found that the use of aluminum in vehicles has been increasing year by year since 1996, and has been on the rise since 2012. Aluminium content has reached 400 lbs/vehicle in 2015 (approximately 181 kg/vehicle), by 2020 it will exceed 450 lb/vehicle (approximately 204 kg/vehicle) and by 2028 it will exceed 550 lb/vehicle (approximately 249 kg/vehicle).


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Although the trend of aluminum alloy lightweight development is clear and clear, the cost factor is still restricting its great strides forward. This is beneficial to low-cost high-strength steel, which is characterized by the application of the tide. The designers of the VW MEB platform have also indicated that they want to choose low-cost steel plates, and say new energy vehicles are more than just "the fashion of the rich class".

In fact, one material cannot completely replace another. Any kind of material, whether from the cost point of view, performance point of view, are each of its own, parallel development. It can only be said that a material, in a certain respect, can better meet the needs of technology or market development.

Battery tray structure design needs more "teaching on the merits"

Steel and aluminum materials in strength, fatigue, elastic modulus, anti-pull, pressure, shearing, bending and other characteristics of the parameters, there are very large differences. The use of metal alloy technology, indeed in some aspects, such as strength characteristics, more pure aluminum, achieved a very significant improvement. However, the aluminum structure can not be equated with steel structure design.

Aluminum has its drawbacks, too.

The density of the battery body is very high, as a battery tray or housing carrying the battery module, has been in the heavy load state. Aluminum's fatigue performance is half that of steel, and its elastic modulus is only one-third that of steel.


Several types of structurecommond in battery aluminum trays


Aluminium battery trays, because of their light weight and low melting point characteristics, generally come in several forms: die-cast aluminum trays, extruded aluminum frames and aluminum plate solder trays (shells), molded upper lids.


Die-cast aluminum tray

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Frame structure

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From the above, although aluminum material has shortcomings, but it has become the current new energy vehicle battery tray of the main material, so as to reduce the total amount of cars. Yuefeng Aluminum Technology as a new energy vehicle battery tray production line manufacturers, for the processing of battery trays to provide a full set of solutions to meet the battery tray accuracy needs. Yuefeng Aluminum Technology Processing Center for new energy vehicle battery trays of rodand and plate custom special pneumatic processing fixtures for processing, gantry processing center for the entire welded base for precision processing.


As an important material for vehicle lightweighting, aluminum must be based on the global market and focus on its sustainability for a long time. The correct application of aluminum in the design requires a deeper understanding of the characteristics of the material. to be able to navigate lightweight applications and keep improving.


Give us a call at +86 18662963676, email us at sales@profiles-aluminum.com to find out how YueFeng Aluminium can help with your aluminum profile/ aluminium solutions design.