New 6xxx Al–Mg–Si Alloy with High Electric Conductivity and Great Bendability for EV Applications

In the past for current-conducting components copper was primarily used. Due to high material price and limited availability of copper, aluminum appears as a great alternative, especially since a higher weight-specific electrical conductivity is achievable and the lightweight construction is optimized. Excellent processing properties make this newest Al–Mg–Si alloy more than just a cheap alternative. Within the product development of the new 6xxx Al–Mg–Si alloy with high electric conductivity, the alloying elements and their solution state played key roles in reducing electrical resistance. Additionally, very good processing properties can be achieved, whereby the material required a specific strength and still has good bendability. During the production process, these properties were generated via a new solution heat treatment approach and subsequent over-aging. Results showed the new aluminum grade achieves an electrical conductivity of 58%IACS (International Annealed Copper Standard) and a crack-free 180° bend according to ASTM E290 (bending factor N = 1). Therefore, this aluminum alloy is ideal for use as a bus bar in EV batteries or other current-conducting applications such as EV charging stations.