Analysis of Aluminum–Cerium Based Conductor Die-Casting Alloys for High Performance Electric Vehicle Powertrain Applications

Lightweighting of electric vehicles is an important consideration to improve range and potentially reduce the vehicle price by downsizing expensive battery and motor components. Aluminum alloys have a combination of light weight, high electrical conductivity and strength that are required in e-motor applications to achieve high power output and efficiency. In this research, Al–Ce based high pressure die casting alloys were investigated in different heat treatment tempers to maximize mechanical properties while maintaining a high electrical conductivity. Testing of tensile properties and electrical conductivity were performed in the as-cast and heat-treated conditions, while microstructural characterization and solidification analysis were performed using scanning electron microscopy and the universal metallurgical simulator and analyzer, respectively. The results suggest that the Al–Ce–Si–Mg alloy had yield strength (YS) exceeding 110 MPa and electrical conductivity of at least 49 pct IACS (28.5 MS/m) in the T5 and T6 conditions, with elevated Fe levels causing a slight reduction in YS and conductivity. This combination of properties makes this alloy a promising alternative to the near pure Al or Cu-based alloys that are currently used in electric induction motors.