Foamed Aluminum: The Revolutionary Material Driving the Next Generation of EV Battery Casing

The Fraunhofer Institute for Machine Tools and Forming Technology (Fraunhofer IWU), a leader in machine tool and forming technology research, has partnered with automotive supplier Amsted Automotive to develop a Battery casing with afoamed aluminum sandwichdesign. This unique material structure consists of two solid aluminum plates with a Foamed aluminum core.

This design is a novel approach to address the ongoing demands of electric vehicles. According to Fraunhofer, "Battery casings in electric vehicles must be impact-resistant, absorb collision energy, prevent short circuits, and be heat-resistant. Efficient heat dissipation is crucial, but the battery also needs to prevent overcooling. The casing must withstand impacts from stones and corrosion from salt spray. The aluminum structure helps strengthen the vehicle's undercarriage, and its lightweight nature increases driving range. Foamed aluminum meets all these requirements." "

A unique feature of the new battery casing is the ability to incorporate cooling structures or a heat storage medium called a phase change material (PCM), as needed. When integrated into closed-cell aluminum foam, PCM can absorb, store, and release significant amounts of heat while changing state (e.g., from solid to liquid and vice versa) without significantly altering its own temperature. This makes the battery casing particularly suitable for efficient thermal management of lithium-ion batteries.

To ensure that aluminum-foam battery casings can be used in mass-produced vehicles, researchers led by Dr. Thomas Hipke and Dr. Rico Schmerler are now focusing on cost-effectiveness. A key factor determining future manufacturing costs is the cost of raw materials. Hipke stated, 'We are increasingly using recycled materials to produce aluminum foam. This is not only more cost-effective but also significantly reduces the CO2 footprint."

As demonstrated by the groundbreaking collaboration between Fraunhofer IWU and Amsted Automotive, aluminum foam is no longer just a cutting-edge material; it has become the ideal choice for high-performance, high-safety battery casings for electric vehicles. As a professional manufacturer of aluminum foam, we understand the unique value of this material and are committed to bringing this innovative solution to market.

We cordially invite you to contact us to learn how to apply our high-quality, customizable aluminum foam solutions to your next-generation electric vehicle platform, jointly driving the safe, efficient, and sustainable development of electric mobility!