-February 7, 2020 at 5:20 a.m. Pacific Time
According to a new patent application, Tesla invented a new aluminum alloy that can maintain high yield strength and high conductivity while still being used for die-casting electric car parts.
We have previously reported that Tesla and SpaceX are collaborating to develop new materials for the earth and space.
They have been forming materials engineering teams to develop new advanced materials for their products.
It started in 2016, when we reported in an exclusive report that Elon Musk hired Apple's alloy expert Charles Kuehmann to lead the materials engineering of his two companies.
Now we understand the new material developed by the Tesla Materials team led by Kuman: a new type of aluminum alloy for die casting.
A new Tesla patent application reveals the new alloy.
In the patent application, Tesla described the current aluminum alloy problems they were trying to solve:
Commercial cast aluminum alloys fall into one of two categories-either with high yield strength or high electrical conductivity. For example, the yield strength of A356 aluminum alloy is greater than 175 MPa, but the electrical conductivity is about 40% IACS. On the contrary, the electrical conductivity of 100.1 aluminum alloy is greater than 48% IACS, but the yield strength is less than 50 MPa. For certain applications, such as components in electric vehicles, such as rotors or inverters, high strength and high conductivity are required. In addition, because it is desired to form these electric vehicle parts through a casting process, forged alloys cannot be used. Instead, it is desirable to form the part through a casting process so that the part can be cast quickly and reliably, such as through low- and high-speed metal injection or high-pressure die casting processes. After casting, suitable alloys must maintain their properties sufficiently for the necessary applications. Poor castability of the alloy usually leads to the observed hot tearing and may cause filling problems, which usually reduces the mechanical and electrical properties of the final casting.
Therefore, Tesla is trying to make alloys with high yield strength and electrical conductivity while being resistant to hot tearing for use in die-casting drive unit components.
Compared with the figures listed above, Tesla claims that its new aluminum alloy can be adjusted to achieve a yield strength of 90 MPa to 150 MPa and a conductivity of 40% IACS to 60% IACS.
They also claim that the new alloy can support die casting:
In one embodiment, the alloy has proper fluidity to ensure that the alloy wets the entire length of the mold and the mold is properly formed, and allows the alloy to resist hot tearing and maintain the desired yield strength when the casting solidifies.
They posted a bunch of test results here:
For materials experts who want to understand how Tesla achieved these results with its new alloy, here is the complete patent application:
View this document on Scribd
Win Tesla Model S Performance, Audi e-tron or Jaguar I-Pace and support charitable causes
FTC: We use car affiliate links that earn revenue. more.
Subscribe to Electrek on YouTube to get exclusive videos and subscribe to podcasts.
Tesla is a transportation and energy company. It sells cars in the "Tesla Motors" division and stationary battery packs for household, commercial and utility scale projects in the "Tesla Energy" division.
Fred is the editor-in-chief and main writer of Electrek.
You can send tips on Twitter (open DM) or via email: fred@9to5mac.com
Through Zalkon.com, you can view Fred's portfolio and get monthly green stock investment advice.
Tesla applies for approval for Texas Gigafactory
Cadillac Lyriq is in the final stage before production
Watch Harley-Davidson’s funny electric bike video
Ariel Rider Grizzly Electric Moped Review
You must be logged in to leave a comment.