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An Experimental Investigation of the Effect of Compression Calibration on the Ductility of AA6061 Extrusions
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Numerical Investigation of Round Profile Production: A Fem-Based Comparison between Friction Stir Extrusion and Conventional Extrusion
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Compensating Property Fluctuations in Cold Extrusion Using Adaptive Dies
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Lightweight Battery Housings from Thin-Walled, Large-Scale Aluminum Profiles by Hot Extrusion
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Calibrating a Lode-Parameter-Dependent Damage Evolution Equation to Cold Extrusion Experiments
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Effect of Chemical Composition on Hot Extrudability and Tribological Behavior of 7000 Series Aluminum Alloys
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Using Tungsten Inert Gas Welding Equipment to Locally Heat Tubes and Achieve Inhomogeneous Thickness in Tube Sinking Processes
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Lightweight Battery Housings from Thin-Walled, Large-Scale Aluminum Profiles by Hot Extrusion

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Abstract:

The transition towards sustainable mobility demands lightweight and modular carrier systems for high-voltage batteries and fuel cells that combine structural efficiency with effective thermal management. This study examines the feasibility of producing thin-walled, large-scale aluminum extrusion profiles for modular battery housings using AA6063. Numerical simulations and experimental trials are conducted to optimize die design and define process limits along the relation between circumscribing circle diameter (CCD) and minimal wall thickness tmin. Furthermore, different quenching methods are used to investigate the influence on surface distortion and final mechanical properties. A streamlined die design with reduced mandrel deflection has enabled defect-free extrusion under controlled conditions for the extrusion of a thin-walled, large-scale profile with a CCD-to-tmin ratio of 138. A narrow process window is identified for extrusion of defect-free profiles. Quenching studies have shown that active cooling methods affect surface deformation but have negligible influence on mechanical properties or microstructure due to efficient heat extraction inherent to thin-wall geometries for the investigated alloy. Scaling experiments using an enlarged cross section by a factor of 2.5 have confirmed similar process stability without wall thickness adjustments, achieving up to 38 % weight reduction compared with conventional designs under industrial conditions.

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Periodical:

Key Engineering Materials (Volume 1048)

Pages:

51-61

DOI:

https://doi.org/10.4028/p-vg6IX7

Citation:

Cite this paper

Online since:

April 2026

Authors:

Oliver Schulz*, Sebastian Wurth, Alessandro Selvaggio, Johannes Gebhard, Yannis P. Korkolis, Patrik Bieker, Thomas Kloppenborg

Keywords:

Die Design, EV, FEM, Process Control, Size Scaling

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Creative Commons CC BY 4.0

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* - Corresponding Author

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