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Battery housings for electric vehicles using CFRP and aluminium foam

Wednesday (24.10.2018)
19:00 - 19:03
Part of:
- Poster Battery housings for electric vehicles using CFRP and aluminium foam 0 Joachim Baumeister
- Poster Manufacturing and characterization of open-cell stainless steel foams by investment casting 1 Jan Frömert
- Poster Interface formation of Mg2X (X = Si, Sn) in cellular Si infiltrated by Mg(Sn) alloys 1 Alexander M. Matz
- Poster Production of microcellular PMMA using the bead foaming technology 1 Mikel Mugica
- Poster Nanocellular PMMA with tunable cellular structure by changing the rheological behaviour of the polymer matrix. 1 Judith Martín de León
- Poster Production of thermoplastic polyurethane foams synthesized with different contents of hard segment and graphene nanoplatelets by the gas dissolution foaming process 1 Ph.D. Mercedes Santiago-Calvo
- Poster Surface functionalized filters for aluminum melt filtration 1 Dr.-Ing. Claudia Voigt
- Poster Nanocellular polymers based on PMMA/sepiolite nanocomposites: characterization of the mechanical behaviour 1 Victoria Bernardo
- Poster Impact resistant foams based on PP/POE blends 1 Ph.D. Santiago Munoz Pascual
- Poster Crosslinked open cell ethylene butyl acrylate copolymer (EBA) foams: properties and applications 1 Ph.D. Eduardo López
- Poster Influence of molecular weight in the solubility,diffusivity and the subsequent cellular structure of polystyrene foams 1 Ph.D. Alberto Ballesteros
- Poster Crushing strength measurement at reticulated ceramic foams ex situ and in situ CT analysis 1 Dr.-Ing. Claudia Voigt
- Poster Initiation of plateau region during compression test of porous metals with aligned unidirectional pores 1 Tomoya Tamai
- Poster Active meta-materials with adjustable pore size 1 Dr. Reza Hedayati
- Poster Polymeric foams 3D numerical mechanical modelling 1 Stefano Tagliabue
- Poster Characterisation of NiTi cellular materials fabricated by the powder-metallurgy spaceholder technique 1 Dr. Karl Dahm
- Poster Accurate separation of open cell metal foams using remote laser cutting technique 1 Robert Baumann
- Poster Generation of artificial foam structures and evaluation of their thermo-mechanical, flow and filtration characteristics (Poster) 1 Christoph Settgast
- Poster Surface modification of magnesium-based foams by Directed Plasma Nanosynthesis 1 Viviana Marcela Posada Pérez

General Topic P: Postersession
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Housings for battery packs of electrical driven vehicles must be light, should have a high stiffness and should exhibit good energy absorption behavior. This can be accomplished by using innovative sandwich materials made of a combination of carbon fibre reinforced plastics (CFRP) and aluminium face sheets and a core layer of aluminium hybrid foam.

Aluminium-epoxy hybrid foams can be obtained by first producing small aluminium foam granules. The foamed granules are then coated with an epoxy adhesive which contains a foaming agent. After filling a hollow structure with the coated aluminium foam spheres the foaming and curing of the adhesive coating is initiated by a mild heat treatment at temperatures between 100 and 200°C. As a result a composite material is formed which consists of aluminium foam spheres embedded in a matrix of epoxy foam (hybrid foam). By placing and curing the coated granules between two face sheets hybrid foam sandwiches can be produced. Sandwich structures have not necessarily to be flat, the technology allows also the production of sandwich-like structures with bent face sheets and closed side surfaces. Insertion of fastening elements can also be done easily.

Relevant material properties of the hybrid foam like compressive strength and the overall achievements in this case study will be presented.


Joachim Baumeister
Fraunhofer Institute for Manufacturing Technology and Advanced Materials IFAM
Additional Authors:
  • Dr. Jörg Weise
    Fraunhofer Institute for Manufacturing Technology and Advanced Materials IFAM, Bremen