The Construction Source Australia

The Construction Source Australia The lighter the vehicle, the longer its range. According to Ducker Worldwide, aluminum is expected to contribute more than half of the anticipated vehicle mass reduction demanded by electric vehicles (EVs) to extend range. Ducker reports that in North America alone, aluminum content in EVs will increase to nearly 565 pounds (256 kilgrams) per vehicle by 2028. The larger the vehicle, the heavier the battery and casing required to optimize the EV’s range. It is the larger EVs, i.e., sedans, SUVs, taxis, trucks and buses, that will realize the greatest benefits from a steel-to-aluminum conversion. In the U.S., a vehicle’s gross weight determines which class of commercial driver’s license (CDL) will be required. Without lightweighting, some EVs could demand a higher-class license or addi- tional endorsements due to the added weight of the battery. In older Europe- an cities like Brussels or London, some bridges and tunnels only allow vehicles up to 3.5 tons in weight, a target that is very difficult to meet for larger EVs without lightweighting. For heavier material transport EVs such as trucks, weight reduction enables an increased payload, providing a signifi- cant monetary benefit. Generally, the larger the vehicle, the higher the payback. Particularly relevant for larger human transport EVs such as buses and taxis, the weight reduction made possible through aluminum provides the added benefit of reduced CO2 emissions and improved air quality, of value not only to vehicle operators, but to the commu- nities they serve. The thermal and anti-corrosion proper- ties of aluminum make it ideal for bat- tery frames. Sea-water resistant, highly formable, highly surfaced aluminum alloys provide the strength necessary to pass side-impact crashworthiness testing, protecting passengers and the battery should impact occur. Casing floor plates made out of aluminum are not only strong, but also capable of resisting corrosion related to weather exposure. These characteristics enable aluminum battery casings to resist weather-related deterioration and im- pact from road debris, minimizing the risk of related fires and further securing passenger safety. Optimizing battery and human safety Extending range Dispersing heat The batteries used in EVs produce energy while charging and decharging, requiring the use of heat exchangers to dissipate heat. But the types of heat exchangers used in vehicle air condi- tioning systems are inadequate to meet this new challenge. Aluminum clad brazing (which connects multiple layers of aluminum together to disperse heat) requires heating in a controlled atmosphere (e.g., a vacuum) to achieve optimum joining. Aluminum heat exchangers designed specifically to meet the challenges presented by electric vehicles can use as many as five types of aluminum sandwiched togeth- er, with the layers providing gradient properties to optimize cooling. These specialized processes and ma- terials address OEM concerns, ensur- ing adequate dissipation of the heat generated by battery-powered vehicles. An experienced aluminum processing partner can help OEMs specify the right process and alloys to meet specific vehicle temperature thresholds, ideally working side by side with OEM engi- neers early in the design process to maximize the performance of electric vehicles. IT IS THE LARGER EVS, I.E, SEDANS, SUVS, TAXIS, TRUCKS AND BUSES, THAT WILL REALIZE THE GREATEST BENEFITS FROM A STEEL -TO-ALUMINUM CONVERSION .