Development of a New Al-Fe-Ni Alloy for Electric Vehicle Applications

The electrification of automotive is growing rapidly, resulting in an increased need for aluminum alloys with high electrical conductivity. The core element of the electric vehicle, besides the batteries, is an electric motor, which replaces the internal combustion engines of a traditional gasoline vehicle. These applications require both high strength and high electrical conductivity. This paper presents the development of a new Al-Fe-Ni aluminum alloy that provides a good combination of mechanical properties and electrical conductivity. The alloy is well suited for high-pressure vacuum die casting (HPVDC). The as-cast microstructures, mechanical properties and electrical conductivity were studied for alloys with different Fe/Ni combination. The relationship between the microstructure and properties is analyzed, and the strengthening mechanisms of the studied alloy are discussed. Based on the experimental results, the new alloy demonstrates excellent potential for electric vehicle applications produced by high-pressure vacuum die casting.