Aluminium for Ultra Low Emission Vehicles (Al-ULEV)

Constellium开发了创新和突破性的高强度铝挤压合金，用于轻型抗碰撞车辆结构，将电池外壳集成到超低排放车辆（ulev）中。挤压物既可以形成保护结构，也可以提供新的热管理系统，可以将电池的工作温度控制到精确的水平，降低热失控的风险，并在城市循环期间优化电池组的工作温度，以减少能量损失。这在制造成本/安装时间方面具有显著优势，同时满足当前的立法要求，为制定新的安全、碰撞管理和能源效率标准提供了机会。电池系统的能量和功率密度都是通过使用铝挤压密集型结构，结合创新的挤压形状设计和先进的制造工艺与高强度铝挤压合金，减少电池外壳重量而提高的。该项目旨在采用颠覆性的高强度铝挤压合金和工艺技术，再加上为英国市场新一代轻型混合动力和电动汽车制造车辆集成结构和电池外壳的定制截面设计，这将对英国政府为英国车队制定的碳减排目标产生重大影响。该项目将设计和开发原型车辆集成系统的挤压组件，并为Gordon Murray设计基于IUK CAAHS项目中正在开发的i-Stream汽车的铝密集型版本的电动汽车的电池外壳。该项目的第二个发展将是捷豹路虎I-Pace的车辆集成和电池盒外壳。长期目标是在英国建立一个基于充分利用可回收铝合金的世界领先的低成本铝挤压型材制造工厂，以便为挤压和ULEV组件制造提供岸上资源。

Constellium has developed innovative and ground breaking high strength aluminium extrusion alloys for use in light weight crash resistant vehicle structures for integration of battery enclosures into ultra low emissions vehicles (ULEVs). The extrusions can form both the protective structures and can provide novel thermal management systems which can control battery operating temperatures to precise levels reducing the risk of thermal runaway and optimising battery pack operating temperatures during the urban cycle to reduce energy losses. This provides significant advantages in manufacturing costs/set up time whilst meeting current legislative requirements, providing the opportunity to define new standards of safety, crash management and energy efficiency. Both energy and power density of battery systems are increased by reducing battery enclosure weight by using an aluminium extrusion intensive architecture, combining innovative extrusion shape design and advanced manufacturing processes with the high strength aluminium extrusion alloys. The project aims to take another major step with disruptive high strength aluminium extrusion alloys and process technology, coupled with bespoke section design for the manufacture of vehicle integration structures and battery enclosures for a new generation of lightweight hybrid and electric vehicles for the UK market that will have a major impact on the UK government's carbon reduction targets for the UK vehicle fleet. The project will design, develop extruded components for prototype vehicle integration systems and for battery enclosures for Gordon Murray Design for an electric vehicle based on the aluminium intensive version of their i-Stream vehicle under development in the IUK CAAHS project. The second development in the project will be for vehicle integration and battery box enclosures, for the JLR I-Pace. The longer term intention is to establish a UK based manufacturing facility for world leading cost efficient aluminium extruded sections based on the intensive use of fully recyclable aluminium alloys in order to provide an on-shore resource for both extrusion and ULEV component manufacture.