The Application of Aluminium Profiles in New Energy Vehicles

The application of aluminium profiles in new energy vehicles (NEVs) is one of the key technologies to promote automotive lightweight, enhance driving range and safety. With the rapid development of the global new energy vehicle industry, aluminium profiles have become the core material to replace traditional steel due to their light weight, high strength, corrosion resistance and easy processing. The following are the main application scenarios and technical trends of aluminium profiles in new energy vehicles.

Vehicle body structural components (lightweight core)

Application components: door frames, roof longitudinal beams, A/B/C columns, anti-collision beams, floor beams, etc.

Advantage–The weight reduction effect is remarkable: The density of aluminium is only one-third that of steel, which can reduce the overall vehicle weight by 10% to 20% and increase the driving range by 5% to 10%.

Good energy absorption: the crumb energy absorption property of aluminium alloy enhances collision safety (for example, the Tesla Mode S adopts an all-aluminium body)

Typical process: extruded aluminium profiles (6000 and 7000 series alloys) are used in frame structures, such as the “aluminium extruded threshold beam” of NIO ET7

Die-cast aluminium + profile combination: the Tesla Model Y adopts an integrated die-cast rear base plate, combined with aluminium profile reinforcing parts, to reduce welding points.

Battery system (Key to safety and range)

Application components: battery pack housing, battery tray, module bracket, cooling system

Advantage–Lightweight: aluminium battery packs are over 30% lighter than steel ones, enhancing energy density.

Thermal management: aluminium profile integrated liquid cooling channel (such as the aluminium tray of BYD Blade Battery)

Anti-corrosion: surface treatment (anodizing, spraying) enhances the resistance to electrolyte corrosion.

Typical process–high-strength 6xxx series aluminium profiles: used for battery pack frames, requiring impact resistance (such as CATL’S CTP technology)

Extrusion + welding process: aluminium profiles are spliced into battery trays, which has a cost advantage over die-cast parts.

Electric drive system

Application components: motor housing, inverter bracket, reducer housing.

Advantage– Good heat dissipation: aluminium has a high thermal conductivity (about 200W/m·K), which is suitable for the heat dissipation requirements of motors.

Vibration and noise reduction: aluminium alloy can reduce the high-frequency vibration noise of the motor.

Typical process–Extruded aluminium profiles + CNC processing: used for motor housings, such as the asynchronous motor housing of Xiaopeng P7.

Thin-walled complex profiles: used for inverter cooling water channels (wall thickness can be less than 2mm).

Chassis and suspension system

Application components: Sub-frame, control arm, steering knuckle

Advantage–Reduce unsprung mass: aluminium suspension components are 40% lighter than steel ones,enhancing handling.

Fatigue resistance: forged aluminium profiles (such as 6082-T6) are used for high-stress components.

Technological trends and challenges

Material innovation–High-strength aluminium alloys: 7000 series (such as 7055), aluminium-lithium alloys (with a weight reduction of over 10%) are used for key structural components.

Recycled aluminium application–Tesla plans to use 50% recycled aluminium in the battery tray of the Cybertruck

Process upgrade– Integrated die-casting + profile composite structure: Tesla’s “Giga Press” die-cast front/rear body, combined with aluminium profile reinforcing beams.

Laser welding + bonding technology: enhancing the connection strength of aluminium profiles (solving the problem of easy deformation in aluminium welding).

Cost and supply chain challenges

Raw material fluctuations: the price of electrolytic aluminium is greatly affected by energy costs, and enterprises need to lock in long-term agreements.

Recycling system: establish a closed-loop recycling network (such as CATL’s cooperation with aluminium enterprises to recycle battery trays)

Future development direction

Multi-material hybrid design: aluminium profiles combined with carbon fiber and magnesium alloy (such as the aluminium-carbon hybrid body of the BMW iX).

Intelligent production: AI algorithms optimize the cross-sectional design of profiles to enhance material utilization.

Policy-driven: China’s “Technology roadmap for energy saving and new energy vehicles” requires that the aluminium consumption per vehicle reach 250kg by 2035 (with a target of 150kg for 2025).

Summary

The application of aluminium profiles in new energy vehicles has changed from “optional” to “mandatory”. In the future, with the advancement of integrated die-casting, recycled aluminium technology and high-end alloys, its penetration rate will continue to increase.