Fabrication of New Energy Battery Housings using Industrial Pure Aluminum Die-Casting

　　Fabrication of New Energy Battery Housings using Industrial Pure Aluminum Die-Casting

　　The fabrication of new energy battery housings using industrial pure aluminum die-casting has become increasingly popular due to the unique properties of aluminum, such as its lightweight, high strength, and good thermal conductivity, which are highly desirable in the new energy vehicle and energy storage industries.

　　The die-casting process for manufacturing new energy battery housings begins with the design of the housing. The design must consider factors such as the size and shape of the battery cells, the required strength and rigidity to protect the cells, and the need for effective heat dissipation. Using CAD software, engineers create a detailed 3D model of the battery housing, taking into account the complex internal structures for battery cell placement, electrical connections, and cooling channels.

　　Once the design is finalized, high-quality industrial pure aluminum is melted in a furnace. The molten aluminum is then injected into a pre-designed die-casting mold under high pressure. The mold is typically made of high-strength tool steel and is designed to accurately form the battery housing with all its required features. The high-pressure injection ensures that the molten aluminum fills the mold cavity completely, resulting in a dense and uniform structure.

　　After the casting process, the newly formed battery housing undergoes a series of post-processing steps. One of the crucial steps is heat treatment. Heat treatment can improve the mechanical properties of the aluminum, such as increasing its strength and hardness. Different heat treatment processes, such as solution annealing, quenching, and aging, can be applied depending on the specific requirements of the battery housing.

　　Surface treatment is also essential for new energy battery housings. As these housings need to protect the battery cells from environmental factors such as moisture, dust, and corrosion, surface treatments like anodizing or powder coating are commonly used. Anodizing can form a protective oxide layer on the surface, enhancing corrosion resistance, while powder coating can provide a durable and aesthetically pleasing finish.

　　In addition, precision machining may be required to create accurate holes, slots, and surfaces for battery cell installation, electrical connections, and assembly with other components. CNC machining techniques are often employed to achieve the high precision needed for these operations. The battery housing also needs to undergo strict quality control checks, including dimensional inspections, non-destructive testing for internal defects, and mechanical property tests, to ensure that it meets the stringent requirements of the new energy battery industry.

　　The use of industrial pure aluminum die-casting for new energy battery housings offers several advantages. The lightweight nature of aluminum helps reduce the overall weight of the battery pack, which is crucial for improving the energy efficiency and range of new energy vehicles. Its good thermal conductivity enables effective heat dissipation, ensuring the safe operation of the battery cells. Moreover, the die-casting process allows for the production of complex geometries in a single step, reducing manufacturing costs and lead times. Overall, the fabrication of new energy battery housings using industrial pure aluminum die-casting is a key technology that contributes to the development and advancement of the new energy industry.

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