About this Abstract |
Meeting |
2025 TMS Annual Meeting & Exhibition
|
Symposium
|
Aluminum Alloys: Development and Manufacturing
|
Presentation Title |
<b> Manufacturing Challenges in Achieving Microstructural and Mechanical Property Requirements for Extruded Aluminum Alloys used in Electric Vehicle Battery Enclosures </b> |
Author(s) |
Gautam Wagle, Sumit Gahlyan, Pankaj Wanjari, Sudharshan R, Raghuram Vemaraju |
On-Site Speaker (Planned) |
Gautam Wagle |
Abstract Scope |
Al-Mg-Si (AA6xxx) wrought extruded alloys are common for manufacture of battery enclosure frames for electric vehicles. The microstructural evolution affecting the mechanical properties during the thermo-mechanical extrusion process of commercially extruded AA6xxx alloys for frame profiles is presented. The hot deformation process of extrusion, press-quench design for precipitation control, and the precipitation hardening aging processes have been designed through multiple lab and computational modelling studies to achieve higher-than-standard combination of mechanical strength and elongation in multi-hollow extrusions. The process solutions designed have been implemented and validated in plant trials. These process modifications have been implemented while considering the dimensional precision requirement on the extruded profiles for vehicle-assembly interfacing of the enclosure frame. In further manufacturing stages, the impact of weld sequencing, and weld parameters on weld penetrations and thermal distortions in the frame have been developed to design industrial process for large-scale manufacturing set-up for battery enclosure frames. |
Proceedings Inclusion? |
Planned: Light Metals |
Keywords |
Mechanical Properties, Process Technology, Joining |