铝制品在新能源汽车轻量化中的创新应用与挑战

The extreme pursuit of extended range by new energy vehicles drives the transition of vehicle body materials towards lightweight design. Aluminum, with its low density (2.7g/cm³), high specific strength (approaching that of high-quality steel), and corrosion resistance, has become a core material for battery pack casings and chassis structural components. The Tesla Model Y adopts an integrated die-casting 6000 series aluminum alloy rear floor, reducing weight by 30% while enhancing vehicle rigidity. The BYD Seal utilizes CTB (Cell-to-Body) technology, integrating blade batteries with a 5000 series aluminum-magnesium alloy body, achieving dual breakthroughs in space utilization and safety. However, the high thermal expansion coefficient of aluminum alloy (23.7×10⁻⁶/K) increases the risk of welding deformation, necessitating the use of laser-MIG hybrid welding technology to control heat input. The 7000 series high-strength aluminum exhibits poor machinability, requiring the use of PCD (Polycrystalline Diamond) cutting tools to reduce tool wear to 0.02mm per thousand cuts.