The Pacific Northwest National Laboratory (PNNL), in collaboration with Magna, has developed a new manufacturing process for creating high-strength aluminum components for electric vehicles (EVs). This innovative method significantly lowers embodied energy by over 50% and reduces carbon dioxide emissions by more than 90% by utilizing scrap aluminum without requiring newly mined ore. The Shear Assisted Processing and Extrusion (ShAPE™) technique transforms leftover aluminum from automotive manufacturing directly into new parts, enhancing material quality while removing the need for an energy-intensive melting phase.
Unlike traditional methods that require lengthy pre-heating and dilution with virgin aluminum, the ShAPE process quickly homogenizes impurities within seconds, resulting in uniform and defect-free aluminum structures. This advancement enables manufacturers to reduce costs and weight, pivotal for extending the driving range of EVs. PNNL’s research indicates that these aluminum parts satisfy industry standards for strength and energy absorption.
Currently, PNNL is exploring the use of higher-strength aluminum alloys for battery enclosures, contributing to a circular economy for recycled aluminum. This effort showcases the potential for sustainable manufacturing solutions in the automotive sector while enhancing the efficiency and environmental performance of electric vehicles.
