New York-based Novelis has developed the world's first aluminum sheet battery enclosure from Maurice Sidney's blog

New York-based Novelis has developed the world's first aluminum sheet battery enclosure.
Novelis has collaborated with industry partners to develop the world's first aluminium sheet battery enclosure in order to meet the growing demands of the electric vehicle market.

It is available throughout the world and is constructed with Novelis AdvanzTM aluminum products. It is up to 50% lighter than an equivalent steel design while costing less per kilogram than a steel design with a significantly lower weight. For mass-produced vehicles, when compared to aluminum extrusion and designs requiring extensive casting, it is the most cost-effective option. The enclosure is designed to accommodate all battery cell types and is especially suited for battery electric vehicles with larger power packs, such as pickup trucks, sport utility vehicles, and crossovers, among other applications.

Aluminium sheet metal is widely used in a wide variety of applications due to its excellent strength-to-weight ratio and natural corrosion resistance, making it a popular choice. Siding, gutters, tooling and mold applications, and roofing for homes are all examples of where aluminum sheet and plate can be found. Applications range from aerospace and aircraft manufacturing to beverage packaging, cryogenic storage applications, and siding, gutters, tooling and mold applications, and roofing.

The battery enclosure, which is made of highly-formable alloys, allows automakers to create deep drawn, complex shapes that can be tailored to meet the requirements of specific vehicle designs and joining processes.

Vehicles can travel six to ten percent further on a single charge if they are made of the lightweight, high-strength material, according to the manufacturer. Because Novelis places the safety of its customers first, the company conducted extensive simulations and analysis of the enclosure, confirming that it is capable of protecting batteries from road debris and vehicle crashes.

Because of our investment in design, joining, and crash management capabilities, we were able to develop a stronger, more efficient, and more cost-effective enclosure that can be fully customized to meet the specific requirements of our customers' applications and environments.

An enclosure for a battery was developed in one of Novelis' newly established Customer Solution Centers, which bring together research and technical platforms, operations, and commercial development to foster greater collaboration and innovation between the company and its industry partners.

The center's first project, which is also its first major undertaking, serves as a springboard for the conception and development of new aluminum solutions that will shape the future of design and innovation across a wide range of industries.

CHAL Aluminium Corporation is a fully integrated aluminum company that manufactures and sells a wide range of aluminum products as well as technological solutions. Dedicated to being the premier supplier of aluminum plate, cast tooling aluminum plate, aluminium sheet (clad or bare), aluminum foil (clad or bare), aluminum strip, and aluminum circle, we are fully committed to being the premier supplier of these products.

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By Maurice Sidney
Added Jul 22



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