Lightweight Optimization of EV Battery Housing Using Scandium-Aluminum Alloys

Lightweight design has always been a vital aspect in the development of modern electric vehicles, and a large portion of the vehicle’s weight comes from the battery pack. In order to improve energy efficiency, reduce greenhouse gas emissions, and reduce users’ driving costs, it is essential to develop lightweight battery pack structures. Scandium-containing aluminum alloys, which have long been used in aerospace applications, provide excellent mechanical performance, low density, good corrosion resistance, and high thermal conductivity. However, their application in the automotive industry is limited. This project aims to explore the potential for reducing battery housing mass and to evaluate the trade-offs between cost and mass by using Sc-Al alloys. In addition, the lightweighting potential was investigated by considering the presence of the flow divider and performing material removal. Structural testing in this work followed UNECE R100 regulations to ensure compliance with electric vehicle battery safety requirements. The housing geometry was modified in SolidWorks, analyzed through finite element simulations in HyperMesh OptiStruct, and subsequently evaluated and ranked using a scoring framework implemented in MATLAB. The results indicate that applying Sc-Al alloys can significantly reduce mass while maintaining safety performance. This study provides valuable strategies for lightweight design for future EV battery housings.