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High-Strength and Corrosion-Resistant Aluminum Extrusion Capability Becomes a Key Focus in EV Battery Tray Manufacturing

High-Strength and Corrosion-Resistant Aluminum Extrusion Capability Becomes a Key Focus in EV Battery Tray Manufacturing

2026-05-19

Industry Background: Higher Structural Requirements for Battery Tray Profiles

EV battery trays have evolved from simple supporting components into integrated structural platforms responsible for multiple engineering functions:

· Battery cell mounting and fixation

· Structural protection and crash energy absorption

· Sealing and environmental isolation

· Thermal conduction and heat dissipation

· Long-term corrosion resistance

In real automotive applications, battery trays are exposed to:

· High humidity environments

· Salt spray conditions (coastal or de-icing regions)

· Thermal cycling stresses

Therefore, material systems must balance mechanical strength, corrosion resistance, weldability, and long-term stability.



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Limitations of Conventional Materials Are Becoming More Visible

Steel-Based Solutions

Steel trays provide rigidity but face limitations:

· High density increases vehicle weight

· Low thermal conductivity affects thermal management

· Corrosion resistance relies heavily on coatings

This limits their suitability under lightweight vehicle design trends.




6xxx Series Aluminum Alloys (6061/6063)

These alloys are widely used due to good extrudability and cost efficiency, but still show challenges in battery tray applications:

· Susceptibility to pitting and intergranular corrosion in harsh environments

· Reduced performance in heat-affected welding zones

· Difficulty balancing strength and corrosion resistance




7xxx Series High-Strength Aluminum Alloys

Although offering higher strength levels, they are limited by:

· Poor extrusion formability

· Limited weldability

· Higher cost

· Insufficient corrosion resistance in certain environments

As a result, large-scale production of complex hollow battery tray profiles remains challenging.




Industry Shift: From Material Selection to Process Capability Optimization

The industry is shifting from material-centric decisions to integrated extrusion system capability development, including:

· Alloy composition optimization for 6xxx systems

· Extrusion temperature window control

· Online quenching and aging coordination

· Die flow channel optimization

· Stable forming of thin-wall multi-cavity structures

This shift highlights that the aluminum extrusion press is no longer only equipment, but a core process control system.



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Key Process Control Factors in Battery Tray Extrusion

1. Controlled Extrusion Temperature Window

Typically maintained around 420–460°C depending on alloy systems, ensuring:

· Stable metal flow behavior

· Reduced grain coarsening risk

· Improved microstructure uniformity




2. Stable Low-Speed Extrusion Strategy

For thin-wall multi-cavity profiles:

· Improves dimensional consistency

· Reduces surface defects such as extrusion ripples

· Enhances wall thickness uniformity




3. Optimized Multi-Cavity Die Design

Porthole die structures help to:

· Improve metal flow distribution

· Reduce internal stress concentration

· Increase structural density

· Lower stress corrosion risk in later stages




Industry Conclusion: Extrusion Capability Becomes a Core Supply Chain Barrier

In the EV battery tray industry, the focus is shifting from “material selection” to:

· Extrusion press stability

· Process window control capability

· Complex hollow profile forming reliability

· Corrosion-resistant structural consistency

As a result, advanced aluminum extrusion systems are becoming a foundational capability in the evolution of EV structural manufacturing supply chains. In response to these core production requirements of the EV battery tray industry, Huanan Heavy Industry Technology Co., Ltd. is committed to providing high-performance aluminum extrusion machines that fully meet and even exceed these industry standards. With decades of experience in manufacturing extrusion equipment and strict quality control systems, our aluminum extrusion machines boast exceptional stability, thanks to their mature structural design of key components and minimal vibration and impact during operation. Equipped with advanced PLC+computer dual control mode and precise hydraulic systems, our machines achieve high-precision process window control, ensuring stable and consistent production processes. Moreover, our heavy-duty extrusion equipment, including the 7500t ultra-large tonnage model, excels in reliable forming of complex hollow profiles, capable of handling large-size and high-precision profile processing needs for EV battery trays. In terms of corrosion-resistant structural consistency, our extrusion machines cooperate with professional surface treatment processes to ensure that the extruded aluminum profiles maintain excellent structural uniformity and corrosion resistance, perfectly adapting to the long-term service requirements of EV battery trays. As a trusted manufacturer with strong technical strength and rich industry experience, Huanan Heavy Industry Technology Co., Ltd. is ready to provide customized aluminum extrusion solutions for global EV battery tray manufacturers, helping enterprises break through supply chain barriers and achieve high-quality development.

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