As supported by a new Patent Application submitted
by Tesla, the car manufacturer has developed aluminum alloys for die-casting of
parts for electric cars.
These aluminum alloys, which besides a high yield strength and a high
extrusion speed can also maintain high thermal conductivity, have been
developed by the Tesla material team headed by alloy expert named Charles
Kuehmann.
An extract from the patent application describes problems with the
current aluminum alloys. The application reveals that the commercial cast
aluminum alloys exist in two forms – either possessing high yield strength or
having high conductivity. For instance, the famous A356 aluminum alloy
possesses the yield strength of over 175 MPa but the conductivity of around 40%
IACS. Conversely, the 100.1 aluminum alloy possesses a conductivity of more
than 48% IACS, but a yield strength of 50MPa. However, for certain parts like
rotors, inverters, stators, etc., within electric vehicles, both high yield
strength and sufficient conductivity are desired. Moreover, it is desirable to
cast the electric-vehicle parts through a quick and reliable low pressure and
high-velocity metal injection or high pressure die casting process. It is
because current cast alloys don’t well serve the application of these parts.
Poor castability of the alloys can lead to hot tearing and result in fill
issues, which decreases the mechanical and electrical properties of the end
cast part. Hence, there’s still a need to develop cast aluminum alloys with
improved conductivity, high strength, and sufficient castability.
Tesla is trying to create alloys that maintain high strength and
improved conductivity while being resistant to hot tearing to be used in die
casting drive unit components. Tesla’s new alloys are expected to solve the
issues with the current aluminum alloys.
Tesla, in its application, revealed that the new aluminum alloys
could be tweaked to achieve the yield strength between 90 MPa to 150 MPa and
conductivity between 40% IACS to 60% IACS. Besides, it also claimed that its
new alloys would support die casting. In other words, the new aluminum alloys
would be available with the proper fluidity to make sure that the alloy wets
the entire length of the mold, the properly formed mold, high conductivity, and
desired yield strength when the cast solidifies. For more visit: https://www.kashishipr.com/
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