BAttery casings from ALuminum alloys with low carbon emissions produced from SCRAP (BAALSCRAP)

Purpose and goal

The project aims to define modified production routes for using scrap aluminum in battery casings which so far relies mainly on virgin aluminum. This transition is crucial for achieving a circular aluminum industry and net-zero emissions in the automotive sector. The project will focus on understanding impurities effect on manufacturing processes, defining tolerance levels for these impurities, and identifying necessary changes in production methods to enable the use of scrap-based alloys.

Expected effects and result

Expected results include defined alloy compositions with higher scrap content and modified forming and welding parameters to ensure properties comparable to aluminum produced from virgin raw materials. The project will significantly reduce CO2 emissions through infrastructure development across the entire battery casing industry. Additionally, the reduced usage of virgin raw materials will result in strengthened European resilience through less aluminum import.

Planned approach and implementation

Initially, the project will conduct a comprehensive literature review and thermodynamic simulations to identify suitable alloy compositions from scrap aluminum. This will be followed by laboratory-scale casting and rolling to produce sheet materials for mechanical testing, corrosion, and welding feasibility experiments. The project will then proceed with forming and deep drawing tests, as well as laser welding trials in larger scale to optimize production parameters for selected alloys.