Materials Innovation in Thermal Management: Advancing Aluminum Alloy Technologies for the Next-Generation Electrical Vehicle Battery Cold Plate

The rapid expansion of the global electric vehicle (EV) market has significantly increased the demand for advanced thermal management solutions. Among these, the battery cold plate is a critical component, essential for maintaining optimal battery temperatures and ensuring efficient operation. As EV batteries increase in size, the thermal management requirements become more complex, necessitating the development of new alloys with enhanced strength and thermal conductivity. These advancements are crucial for the effective dissipation of heat and the ability to withstand the mechanical stresses associated with larger and more powerful batteries. The evolving performance demands of EVs are driving material innovation within the thermal management sector. This study aims to explore global heat exchanger market trends from a materials perspective, focusing on the evolution of alloy mechanical, fatigue, and thermal properties. Specifically, we investigated the transition from traditional 3003 alloys to modified 3xxx series alloys, and the potential for 6xxx series alloys to deliver further advancements. The mechanical properties of these alloys were assessed through both natural and artificial aging processes. Notably, the yield strength of the 6xxx alloy doubled following the post-braze artificial aging process. Additionally, the thermal conductivity of the alloys was evaluated to identify materials that could provide significant improvements in heat exchanger applications. The thermal conductivity of the 6xxx alloy increased by 10% with post-artificial aging. By comparing the performance of traditional and modified alloys, this study provides insights into the future direction of material development for thermal management in the EV market. The results underscore the importance of material innovation in addressing the growing demands of the next-generation heat exchanger market within the EV industry.