Specialized aluminum alloy configurations engineered for the demanding thermal, structural, and durability requirements of EV and ESS battery packs.
The baseline reliability of any liquid cooling system is dictated by its material properties. By carefully balancing thermal conductivity with mechanical strength and chemical resistance, we ensure that the cooling plates perform consistently under continuous thermal cycling and varied environmental conditions.
| Performance Factor | Technical Focus | System Benefit |
|---|---|---|
| Thermal Transfer | Uniform heat dissipation across the plate surface. | Mitigates localized hot spots and maintains battery cells within their optimal operating temperature range. |
| Corrosion Resistance | High resistance to pitting and intergranular corrosion when exposed to water/glycol mixtures. | Ensures long-term structural integrity and minimizes the risk of coolant leakage over the product lifecycle. |
| Strength-to-Weight Ratio | Balancing internal pressure resistance and structural demands with lightweighting targets. | Supports overall battery pack structural requirements without compromising system energy density. |
| Brazability | Formulation optimized for Controlled Atmosphere Brazing (CAB) and vacuum brazing. | Provides consistent clad flow, reliable joint formation, and high manufacturing yield. |
| Alloy | Performance | Post-Braze Properties | Environmental Metrics | ||||
|---|---|---|---|---|---|---|---|
| Brazing capability |
Age hardenable |
Yield Strength [MPa] |
Tensile Strength [MPa] |
Anti Corrosion |
Carbon Intensity |
Recycled Content |
|
| 3003 (Standard High Mn) |
GOOD | None | 40 | 110 | GOOD | 3-6 | Medium |
| 3003M (Modified, Cu other element added) |
GOOD | None | 55 | 160 | MID | 3-6 | High |
| GOOD | None | 60 | 155 | HIGH | 3-6 | High | |
| MID | None | 65 | 170 | HIGH | 3-6 | High | |
| 6061 (High Mg high strength) |
MID | YES | 85 | 150 | GOOD | 3-6 | High |
| Thickness [mm] |
Temper | Clad ratio | Series | |
|---|---|---|---|---|
| Clad | 0.08mm-3mm | Temper O Temper H14 Temper H18 Temper H24 |
5%-15% | 4 series 6 series 7 series |
| Component / Function | Recommended Alloy Series | Typical Examples | Primary Characteristics |
|---|---|---|---|
| Base Plate & Flow Channels | 3000 Series | AA3003 | Optimal balance of formability, thermal conductivity, and corrosion resistance for fluid containment. |
| Structural Enhancements | 6000 Series | AA6061 | Enhanced mechanical strength and rigidity; applied in designs requiring specific load-bearing capabilities. |
| Clad / Brazing Layers | 4000 Series | AA4343, AA4045 | Precise melting points; engineered to form robust, hermetic joints between the flow channel and base plate. |
Our thermal design and materials engineering team is available to support your project from initial material selection and thermal simulation to prototyping and mass production.
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