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.
Highlights
With the increasing environmental impact from the automotive industry, batterypowered electric vehicles (BEVs) have become increasingly popular
An induction motor is an important system component in integrated BEVs working on different operating conditions [1], since a rotor of the induction motor is configured of an electrical sheet, a rotor bar, and end-ring (Figure 1), which are usually manufactured by high pressure die casting (HPDC) or sand casting
The second and third digits i1nxdxi.cxate the purity of the aluminuPmur[e5A].luAmminounmg t(h≥e99c%as)t Al alloys, 2xx.x and 3xx.x series a2rxex.oxften employed for various cast automCootpivpeercomponents for high strength and cast abi3lixtixe.xs, respectively
Summary
With the increasing environmental impact from the automotive industry, batterypowered electric vehicles (BEVs) have become increasingly popular. To improve the efficiency of the induction motor, copper with a high electrical conductivity and low resistivity, is often used. Aluminum and its alloys are very popular for many applications due to i appearance, light weight, fluidity, castability, fabricability, weldability, physical an mechanical properties, hot tear resistance, and corrosion resistance [4]. The addition silicon to aluminum reduces its melting temperature and improves fluidity. Th aluminum alloys with silicon have good castability, resistance to hot tea2rionfg2,5reasonab mechanical properties, and excellent corrosion resistance. Aluminum and its alloys are very popular for many applications due to its appearance, light weight, flu2i.dCiltay,ssciafsitcaabtiiolintyo, ffaAblruicmabiniluitmy, Awlellodyasbility, physical and mechanical properties, hot tear resistaAnclue,mainndumcorarlolosyiosncarnesbisetadnicveid[e4d]. The secon single digit (xXxx), if different from 0, indicates a modification of the specific alloy, an. The second and third digits i1nxdxi.cxate the purity of the aluminuPmur[e5A].luAmminounmg t(h≥e99c%as)t Al alloys, 2xx.x and 3xx.x series a2rxex.oxften employed for various cast automCootpivpeercomponents for high strength and cast abi3lixtixe.xs, respectively
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