Al Alloys and Casting Processes for Induction Motor Applications in Battery-Powered Electric Vehicles: A Review

Abstract

With the rapid expansion of battery-powered electric vehicles (BEVs) in the automotive industry, research interest in lightweight Al alloys as well as their casting processes and applications has increased considerably. The substitution of castable aluminum alloys with superior strengths and electrical conductivity for copper reduces the weight and size of electric induction motors, and improves the energy efficiency and driving range of the BEVs. The present article was intended to give a general introduction into the common cast Al aluminum alloys and their relevant processes, as well as to motivate the development of high strength and conductive Al alloys for the practical realization of Al applications in the motors of the BEVs. A number of cast alloy systems containing Cu, Si, Ni, Mg, Fe, and Ti were evaluated, in comparison to nanostructured wrought Al alloys. The conventional casting processes suitable for Al alloys, high pressure die casting, squeeze casting, and sand casting were described. Strengthening mechanisms including solid solution strengthening, precipitation strengthening, dislocation accumulation strengthening, and grain boundary strengthening were presented. The phenomenon of electrical conduction for Al alloys was outlined. The mechanical properties and electrical properties of the recently developed Al alloys for casting and deformation processes were comprehensively listed and critically reviewed in association with microstructural characteristics.

Effect of Sc, Hf, and Yb Additions on Superplasticity of a Fine-grained Al-0.4%Zr Alloy

“…2, 5, 7, 8, the volume fraction of precipitating (fv) Al3X particles will be noticeably higher than in other alloys (alloys No. 1,3,4,6). Table 1 shows that alloys No.…”

“…Such a modern aircraft onboard network is several kilometers long, that is why replacement of copper wires with aluminum ones helps reduce the weight of an onboard network and improve the efficiency of aviation technology. Thin aluminum wires find applications in the automotive industry [3] and in the modern power industry [4]. Eutectic aluminum alloys with a high content of rare earth elements (REEs) and commercial conductor Al-Mg-Si alloys are often used to produce wires [1,2,5,6].…”

Effect of Er, Si, Hf, Nb Additives on the Thermal Stability of Microstructure, Electrical Resistivity and Microhardness of Fine-Grained Aluminum Alloys Al-0.25%Zr

“…Using Equation ( 5), one can estimate the magnitude of coefficient m, which depends on the dominating diffusion mechanism limiting the growth intensity of the secondary particles [100,102]. According to (5), the quantity 1/m corresponds to the slope of the curve R(t) in the logarithmic axes lnR -lnt. Note that the magnitude of the coefficient m determines the dominating mechanism of the particle growth [100,102].…”

“…At present, high-strength aluminum alloys with increased electrical conductivity are considered as substitutes for copper alloys applied widely for making the fine wires (0.2-0.5 mm) of the on-board wiring of modern aircrafts and automotive. International companies use fine bimetallic wires copper-clad aluminum wires made from complex aluminum alloys for novel airplane and automotive electrical wiring [1][2][3][4][5]. The fine aluminum wires can be applied efficiently also in car-building industry, electric power engineering, power transmission applications, etc.…”

Synergetic effect of milling speed and duration on particle morphology and mechanical properties of nanocrystalline Al matrix containing SiC

“…Aluminium matrix composites (AMCs) reinforced by SiC particles have tremendous applications in aerospace [1][2][3], electric vehicles [3][4][5][6] and urban air mobility [7] due to the excellent mechanical and thermal properties of SiC. Generally, the final performance of the AMCs depends on the volume fraction, size and dispersion of reinforcements.…”