Constellium-led ALIVE collaborative research project achieves 12 to 35 percent weight savings for EV battery enclosures with optimized designs and manufacturing processes
Rhea-AI Summary
Constellium (NYSE: CSTM) has announced the successful completion of its ALIVE project, focused on developing lightweight aluminium battery enclosures for electric vehicles. The £15m collaborative research project, led by Constellium's University Technology Center at Brunel University London, achieved weight savings of 12% to 35% compared to existing designs while meeting performance targets.
The project involved six industrial partners and two university technology partners, utilizing Constellium's high-strength alloys and various joining and forming technologies. Full-scale prototypes were built and tested, demonstrating superior performance in crash tests, vibration, and fire resistance. The team also developed cost models and conducted a life cycle assessment, validating the benefits of aluminium solutions over steel designs.
Positive
- Achieved 12% to 35% weight savings in battery enclosure designs
- Successfully developed and tested full-scale prototypes meeting severe testing requirements
- Demonstrated superior performance of coated aluminium solutions for fire resistance
- Created a full-scale battery enclosure prototyping line
- Developed cost models to support future industrialization decision-making processes
- Validated benefits of aluminium solutions over steel designs through life cycle assessment
Negative
- None.
Insights
The ALIVE project's results are highly significant for the EV industry. Achieving
The project's success in meeting rigorous safety standards while reducing weight demonstrates the viability of aluminium as a superior material for battery enclosures. This could trigger a shift in material choice across the industry, potentially benefiting aluminium suppliers like Constellium.
The development of cost models and a full-scale prototyping line suggests that these innovations are ready for industrialization, which could accelerate adoption by major automakers. This positions Constellium favorably in the rapidly growing EV market.
The ALIVE project's use of Constellium's HSA6® and HCA6® alloys showcases the potential of advanced aluminium alloys in critical EV components. The superior performance in crash tests and fire resistance demonstrates that these materials can meet or exceed the stringent safety requirements of the automotive industry.
The project's success in implementing various joining and forming technologies is a significant technical achievement. This versatility in manufacturing processes could lead to more flexible and efficient production methods for battery enclosures, potentially reducing costs and improving quality.
The validation of aluminium solutions through a cradle-to-grave LCA adds credibility to the environmental benefits of these designs, which is important for automakers focusing on sustainability.
This breakthrough positions Constellium to potentially capture a larger market share in the rapidly growing EV sector. The
The
The collaboration with major OEMs like BMW and Volvo could result in long-term supply contracts, providing stable revenue streams. Additionally, the adaptability of the designs to various battery enclosure strategies positions Constellium to cater to a wide range of customers, potentially boosting sales across different vehicle segments.
PARIS, Sept. 04, 2024 (GLOBE NEWSWIRE) -- Constellium (NYSE: CSTM) today announced the results of its collaborative research project ALuminium Intensive Vehicle Enclosures (ALIVE). Constellium’s University Technology Center (UTC) at Brunel University London was the lead partner of the project focused on developing structural aluminium battery enclosures for electric vehicles. The
The consortium, comprised of six industrial partners (BMW, Constellium, EXPERT Technologies Group, Innoval Technology, Powdertech and Volvo) and two university technology partners (BCAST (Brunel University London) and WMG (University of Warwick)), developed novel aluminium battery enclosure designs meeting challenging performance, manufacturing, weight, and cost targets for the project’s OEM partners, BMW and Volvo. The project’s multidisciplinary team investigated and implemented a wide range of joining and forming technologies in combination with Constellium’s family of high-strength and high-crash alloys, Constellium HSA6® and Constellium HCA6®, to create high-performance, lightweight, and cost-efficient aluminium designs.
The project also enabled the creation of a full-scale battery enclosure prototyping line. Several different 1:1 scale prototypes have been built for a variety of vehicle platforms, passing a range of severe testing requirements such as side pole crash/side impact, bottom intrusion, acceleration, shock, vibration, and leak testing. The team also demonstrated the superior performance of coated aluminium solutions for fire resistance. The battery enclosure designs and associated manufacturing technologies developed as part of the ALIVE project enabled the team to save between
ALIVE also supported the development of cost models to quantify manufacturing costs and minimize capital expenditures to support future industrialization decision-making processes. Given the rapidly evolving EV market, the team had to adapt quickly and develop various technologies supporting OEMs’ structural, non-structural, module-to-pack, and cell-to-pack battery enclosure strategies. Additionally, the consortium proposed a full cradle-to-grave Life Cycle Assessment (LCA), validated by an external panel, demonstrating the benefit of aluminium solutions over ancillary steel designs.
“Today, we celebrate the impressive achievements of the ALIVE project and the power of collaboration between OEMs and suppliers to innovate the future of the automotive industry,” commented Alexandra Bendler, President of Constellium’s Automotive Structures & Industry business unit. “Together, we are paving the way toward sustainable electrification, offering unparalleled battery enclosure designs that exceed performance and cost requirements while providing significant weight savings. Thank you to all the teams and partners involved for their exceptional contributions.”
The Constellium team is already adapting the design philosophies to other enclosure types, such as chest battery packs for trucks and SUVs, as well as validating the use of high-recycled content alloys in such demanding aluminium product forms to further improve their carbon footprint.
Constellium designed and produced the aluminium extrusions for the project at its University Technology Center (UTC) at Brunel University London, its dedicated center of excellence for developing and testing aluminium extrusions and prototype automotive components at scale.
About Constellium
Constellium (NYSE: CSTM) is a global sector leader that develops innovative, value-added aluminium products for a broad scope of markets and applications, including aerospace, automotive and packaging. Constellium generated
www.constellium.com
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FAQ
What weight savings did Constellium's ALIVE project achieve for EV battery enclosures?
What alloys did Constellium (CSTM) use in the ALIVE project for battery enclosures?
How much funding did the ALIVE project receive and from where?
What types of tests did the Constellium (CSTM) ALIVE project battery enclosures pass?
