5/6/2023 0 Comments Car battery box“This facility is an important part of America’s EV battery infrastructure, and this is just the start,” said Ascend Elements CEO Mike O’Kronley. The facility began partial operations in August 2022 and now has an annual capacity to process 30,000 metric tons of used lithium-ion batteries and manufacturing scrap – equal to 70,000 electric vehicle batteries per year. As demand for electric vehicles increases, lithium-ion battery recycling is becoming an increasingly important part of the EV battery materials supply chain. Located in Covington, Georgia, the $50 million Base 1 facility is North America’s largest electric vehicle battery recycling facility. (AP) - Ascend Elements celebrated the grand opening of its first commercial-scale lithium-ion battery recycling facility this week. Innovations like 3D roll-forming AHSS to fabricate cross meshes that work under compression will really open up the way designers think about achieving maximized axial load performance – both lateral and longitudinal.ĭo you have a BEV design challenge that you would like to solve using AHSS steels? It’s never too early to contact us for your next project.ATLANTA, Ga. We’ll provide auto designers with AHSS simulations, such as the side crash simulations, that show how to improve the performance of critical safety components, like improving the performance of floor cross members by a factor of two.Īnd finally we want to demonstrate innovative new designs and production methods for AHSS steels, such as 3D roll-forming for more space-efficient EV battery boxes. We also want OEMs to achieve higher levels of AHSS material utilization so they can realize additional savings. We want to appeal to OEMs’ self-interest, motivating them to use AHSS steels for critical components in battery electric vehicles – while achieving the same weight savings as higher-priced aluminum or other CO 2-intensive materials. In an event of a crash, this peak load must not be exceeded. What is critical in this application is the peak load, not the energy absorption. The simulation results show that an optimized cross member can more than double the crash load transfer performance over the square-shaped profile. Notable is that a profile which has one or more grooves is actually larger by surface area and has to have a thinner gauge Docol 1700M in order to keep the same total weight. Obvious in Figure 8 is that: 1) a large radius is better than a small radius, and 2) that grooves have a major effect by eliminating local buckling – they provide more radiuses through which forces can travel. One way of restraining local buckling is to make the wide segments of a profile less wide by means of a groove and increasing the level of material utilization. However, all these square-tube profiles require some type of welding and SSAB needs to perform more testing to determine if the beam’s welds ductile enough to handle deformation without cracking.ĪHSS steels have a very high yield point and therefore the phenomena called “local buckling” must be considered for wide and thin parts that work in compression: see SSAB’s Design Handbook. Would making an energy-absorbing sill/rocker beam from Docol 1700M AHSS withstand crash deformation without cracking? Initial Docol prototypes show that it can. SSAB has determined which profile – with single-wall ribs – allows for thicker outer walls and delivers a crash performance that is similar to that of an aluminum beam, with the weights being the same for both materials. And, according to the simulations, the thickness of the outer shell of the profile is more important than the thickness of the ribs. The welded square tube approach seems to work, but the abutting ribs are doubly thick. To try to keep fabricating costs and complexity down, many simulations have been done using square-shaped tubes welded together. Therefore, all these profiles have some sort of inner structure. displacement simulations show that an AHSS steel cross section must have some sort of rib to work properly. The wall thickness for each design profile is adjusted so the weight of the Docol 1700M sill beam is the same as the 6082 T6 aluminum sill beam.
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