Nowadays, aluminum has been widely used in new energy vehicles. Aluminum alloy can be applied to structural components and parts such as the body, engine, and wheels. In the context of energy-saving environmental requirements and the development of aluminum alloy technology, the usage of aluminum in automobiles has been increasing year by year. Relevant data shows that the average aluminum usage in European automobiles has increased by three times since 1990, from 50 kilograms to the current 151 kilograms, and is expected to increase to 196 kilograms by 2025. 

Aluminum for new energy vehicles 

Unlike traditional cars, new energy vehicles are powered by batteries. The battery tray consists of individual battery units, and the modules are fixed on the metal casing in a way that facilitates heat management. This plays a crucial role in ensuring the normal and safe operation of the batteries. The weight of the batteries directly affects the vehicle load distribution and the range of the electric vehicle. 

The aluminum used in new energy vehicles mainly includes 5 series (Al-Mg series) and 6 series (Al-Mg-Si series), etc. It is known that the aluminum trays for batteries mainly use 36 series aluminum alloy. 

Several common structural types of battery aluminum trays 

For battery aluminum trays, due to their light weight and low melting point characteristics, there are usually several forms: die-cast aluminum trays, extruded aluminum frames and aluminum plate joined and welded trays (enclosures), formed covers, etc. 

Cast aluminum tray 

The additional structural feature is a single die-casting process, which reduces the material burn and strength issues caused by the welding of the tray structure. The overall strength characteristics are better. The tray of this structure has no obvious features of a frame structure, but its overall strength can meet the requirements for battery cutting. 

2. Pressing aluminum welding frame structure. 

This structure is more common. It is also a more flexible structure. Through the welding and processing of different aluminum plates, it can meet the requirements of different energy levels. At the same time, you can easily modify the design and adjust the materials used. 

3. The framework structure is the form of the tray. 

The aluminum frame structure used in new energy vehicles is more conducive to lightweighting and also more beneficial for ensuring the strength of other components. 

The structure of the battery aluminum tray also follows the design of a frame structure. The external frame mainly fulfills the load function of the entire battery system. The internal frame mainly fulfills the load function of sub-modules such as modules and water-cooled plates. The intermediate protective surface between the inner and outer frames mainly accomplishes the functions of gravel impact resistance, waterproofing, heat insulation, etc., for isolating and protecting the battery pack from the outside world. 

New energy vehicles are different from traditional vehicles. They are powered by batteries to drive the vehicles. Due to the weight of the batteries, the limitations of battery lifespan and mileage, as well as the high pressure of energy conservation and emission reduction policies, in vehicle design and data application, body lightweighting has become the first issue that automotive enterprises need to consider. Therefore, battery-powered new energy vehicles are more urgently in need of weight reduction compared to existing vehicles, which has also opened up an increasingly broad market space for the aluminum industry. 

Aluminum, as an important material for new energy vehicles, should focus on the global market and pay attention to long-term sustainable development. With the increase in the market share of new energy vehicles, the aluminum used in new energy vehicles is expected to grow by 49% in the next five years.