Aluminium Die Casting A356 Electric Vehicle Battery Packs
Structural Parts
Overview of This Product:
This product is carefully selected for their ideal balance of
strength and malleability. In the die casting process, molten
aluminium is forcefully injected into precisely engineered dies
under high pressure. This enables the creation of intricate and
accurate shapes that are crucial for the proper functioning of
electric vehicle battery packs. Following the casting, a meticulous
nickel plating procedure is applied. The parts are first prepped to
ensure a clean surface, and then a layer of nickel is electroplated
on, enhancing both the surface properties and overall performance.
Comparison of Aluminium Die Casting with Other Manufacturing
Processes:
Comparison Items | Aluminium Die Casting | Sand Casting | Machining | Forging |
|---|
Complexity of Geometry | High, can produce intricate shapes | Moderate, limited by mold making | Moderate to low, depends on tooling | Low, mainly for simple shapes |
Dimensional Accuracy | High, tight tolerances | Moderate, may require machining for precision | High, but can be affected by tool wear | Moderate, may need post-forging machining |
Production Volume | Suitable for mass production | More suitable for small to medium production runs | Suitable for small to medium production, high setup cost for mass
production | Suitable for medium to high production of simple parts |
Surface Finish | Good, smooth surface | Rough, requires significant post-processing | Varies, may need additional finishing | Usually rough, needs machining for smooth finish |
Material Utilization | High, near-net-shape, less waste | Moderate, some waste from gating and risers | Low, significant material removal | Moderate, some material waste during shaping |
Cost | High initial die cost, low unit cost for mass production | Low initial tooling cost, higher unit cost for small runs | High setup and machining cost per part | High initial cost for dies and equipment, cost-effective for large
volumes |
Common Surface Treatments for Aluminum Die Casting:
1. Anodizing: Improves corrosion resistance and offers a decorative,
customizable finish.
2. Powder Coating: Applies a tough, wear-resistant coating available in a wide range
of colors.
3. Polishing: Produces a smooth, shiny surface for both aesthetic appeal and
functional benefits.
4. Sandblasting: Creates a consistent matte texture, enhancing surface appearance
and adhesion.
5. Electroplating: Deposits a protective metal layer (e.g., zinc or nickel) to
increase durability and resistance to wear.
Applications in Electric Vehicle Battery Packs:
1. Battery Pack Enclosures
The nickel-plated aluminium die-cast parts are commonly used for
battery pack enclosures. These enclosures protect the battery cells
from external impacts, moisture, and other environmental factors.
The corrosion resistance and mechanical strength of the
nickel-plated parts ensure the safety and reliability of the
battery pack.
2. Connecting Brackets and Frames
They serve as connecting brackets and frames within the battery
pack, holding the battery cells and other components in place. The
improved electrical conductivity and mechanical properties of the
nickel-plated parts help in maintaining stable electrical
connections and structural integrity.
3. Electrical Terminal Components
For electrical terminal components in the battery pack, the nickel
plating provides a corrosion-resistant surface for electrical
contacts. This ensures reliable electrical connections and reduces
the risk of electrical failures due to corrosion.
