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<p>The automotive industry faces mounting pressure to reduce its environmental footprint, particularly in the electric vehicle (EV) era. While EVs mitigate tailpipe emissions, the production of energy-intensive components like aluminum remains a sustainability challenge. Battery housings, critical to structural integrity and crash safety, traditionally rely on extruded aluminum profiles for their outer frames. This study proposes a sustainable alternative: wood-steel hybrid profiles for EV battery housing applications. Quasi-static three-point bending tests were performed on hybrid beams with distinct wood cores (birch, poplar, and paulownia) encased in rectangular profiles made from high-strength complex-phase steel sheets. Performance metrics—including maximum force, bending stiffness, and specific energy absorption—were evaluated and compared to numerical simulations of mass-equivalent three-chambered aluminum beams (ductile EN AW 6061-O and high-strength EN AW 6061-T6), which serve as simplified analogues of real-world extrusion profiles. Results demonstrate that wood-steel hybrid beams outperform ductile aluminum counterparts, with poplar- and birch-core hybrids achieving 88% higher peak forces and 98% greater energy absorption. Paulownia-steel hybrids exhibited moderate improvements, delivering 60% higher peak forces and 34% greater energy absorption. Compared to high-strength EN AW 6061-T6, hybrids matched peak forces and energy absorption at low intrusion levels but provided 76% higher energy absorption under large deformations. This research highlights the potential of wood-steel hybrids to enhance crash safety while significantly reducing the carbon footprint of vehicle structures. By leveraging renewable materials and surpassing the performance of conventional alternatives, these hybrid beams offer a compelling solution for advancing sustainable automotive design, particularly in key components such as EV battery housings.</p>

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Wood-steel hybrid beams for electric vehicle battery housings: a comparative study with aluminum profiles in bending load case

  • 期刊论文

  • 出版模式：

    开放获取

  • 发表日期：

    2025年5月19日

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  • Sebastian Wurm,
  • Markus Wagner,
  • Georg Baumann,
  • Kevin Vitzthum,
  • Harald Sehrschön,
  • Thomas Krenke,
  • Florian Feist

摘要

The automotive industry faces mounting pressure to reduce its environmental footprint, particularly in the electric vehicle (EV) era. While EVs mitigate tailpipe emissions, the production of energy-intensive components like aluminum remains a sustainability challenge. Battery housings, critical to structural integrity and crash safety, traditionally rely on extruded aluminum profiles for their outer frames. This study proposes a sustainable alternative: wood-steel hybrid profiles for EV battery housing applications. Quasi-static three-point bending tests were performed on hybrid beams with distinct wood cores (birch, poplar, and paulownia) encased in rectangular profiles made from high-strength complex-phase steel sheets. Performance metrics—including maximum force, bending stiffness, and specific energy absorption—were evaluated and compared to numerical simulations of mass-equivalent three-chambered aluminum beams (ductile EN AW 6061-O and high-strength EN AW 6061-T6), which serve as simplified analogues of real-world extrusion profiles. Results demonstrate that wood-steel hybrid beams outperform ductile aluminum counterparts, with poplar- and birch-core hybrids achieving 88% higher peak forces and 98% greater energy absorption. Paulownia-steel hybrids exhibited moderate improvements, delivering 60% higher peak forces and 34% greater energy absorption. Compared to high-strength EN AW 6061-T6, hybrids matched peak forces and energy absorption at low intrusion levels but provided 76% higher energy absorption under large deformations. This research highlights the potential of wood-steel hybrids to enhance crash safety while significantly reducing the carbon footprint of vehicle structures. By leveraging renewable materials and surpassing the performance of conventional alternatives, these hybrid beams offer a compelling solution for advancing sustainable automotive design, particularly in key components such as EV battery housings.