Al Alloys and Casting Processes for Induction Motor Applications in Battery-Powered Electric Vehicles: A Review

With the rapid expansion of battery-powered electric vehicles (BEVs) in the automotive industry, research interest in lightweight Al alloys as well as their casting processes and applications has increased considerably. The substitution of castable aluminum alloys with superior strengths and electrical conductivity for copper reduces the weight and size of electric induction motors, and improves the energy efficiency and driving range of the BEVs. The present article was intended to give a general introduction into the common cast Al aluminum alloys and their relevant processes, as well as to motivate the development of high strength and conductive Al alloys for the practical realization of Al applications in the motors of the BEVs. A number of cast alloy systems containing Cu, Si, Ni, Mg, Fe, and Ti were evaluated, in comparison to nanostructured wrought Al alloys. The conventional casting processes suitable for Al alloys, high pressure die casting, squeeze casting, and sand casting were described. Strengthening mechanisms including solid solution strengthening, precipitation strengthening, dislocation accumulation strengthening, and grain boundary strengthening were presented. The phenomenon of electrical conduction for Al alloys was outlined. The mechanical properties and electrical properties of the recently developed Al alloys for casting and deformation processes were comprehensively listed and critically reviewed in association with microstructural characteristics.

随着电池驱动电动汽车（BEV）在汽车行业的迅速扩张，对轻质铝合金及其铸造工艺和应用的研究兴趣大幅增加。用具有优异强度和导电性的可铸铝合金替代铜，可减轻电动感应电机的重量和尺寸，并提高电池驱动电动汽车的能源效率和续航里程。本文旨在对常见的铸造铝合金及其相关工艺进行一般性介绍，并推动高强度和导电铝合金的开发，以实现铝合金在电池驱动电动汽车电机中的实际应用。与纳米结构的变形铝合金相比，对一些含铜、硅、镍、镁、铁和钛的铸造合金系进行了评估。描述了适用于铝合金的常规铸造工艺，如高压压铸、挤压铸造和砂型铸造。介绍了固溶强化、沉淀强化、位错累积强化和晶界强化等强化机制。概述了铝合金的导电现象。结合微观结构特征，全面列举并批判性地综述了近期开发的用于铸造和变形工艺的铝合金的力学性能和电学性能。