Battery Housing

Development & Production

GF Casting Solutions contributed to the development of this aluminum battery housing for Renault’s electric vehicle in many ways: from component development, design and optimization, prototyping, process development for casting and assembly, to various tests and simulations. While the conventional process requires the assembly of more than 100 individual parts, GF managed to integrate everything into one part, and avoid complex post-processes such as welding and milling. Instead, GF developed the welding of the covers using the friction stir welding process. The serial production of the product takes place at the plant in Altenmarkt (AT).

Challenges & Special Features

During production, the main challenge was to avoid deformations after machining and to ensure that no leaks occurred after welding. The size of the part, closed by welded covers, also deserves special attention as it is cast in one piece. Additionally, the component features an integrated cooling system as well as integrated connection points for surrounding body and structure parts. According to the customer, the vehicle emits about 75 % less CO2 per kilometers than identical models with combustion engines.

"Renault is an important customer for GF Casting Solutions with a lot of growth potential, and this project is a milestone in terms of our development in the field of new e-mobility components."

 

Christophe Buch
KAM ZF, OEM France

"In addition to developing a design that meets the customer’s requirements, we also reduced the number of assembly steps, simplifying the process and avoiding labor-intensive joining and post-processes such as welding and milling"

Christian Graf
Team Leader Validation

Highlights

  • High functional integration
  • Integrated active cooling system
  • High strength and stiffness
  • Lightweight

Features

Customer
Renault
Vehicle   Captur E-Tech PHEV
Process Aluminum high-pressure die-casting
Material AlSi10MnMg
Weight 15.0 kg
Value Chain Casting, trimming, machining, welding, assembly, leakage testing

Have a look at other components: