E-Mobility

Accelerating the transformation to sustainability

The automotive industry is currently experiencing a transformation following new requirements for lightweight construction and e-mobility. Original Equipment Manufacturers (OEMs) and Tier-1 suppliers find themselves continually confronting new part designs that demand innovative manufacturing processes and prototyping support. Battery Management Systems (BMS) monitor and control the temperatures during the charging and discharging processes of the battery. As they are integrated into the coolant circuit to regulate the temperature of the battery, these circuits of battery trays, stator housings and heat exchangers require a watertight and gastight connection. In the production of vehicle components from heat-treated aluminum alloys, Friction Stir Welding achieves very high strength due to its low heat input.

HV inverter housings

For inverter housings of electric vehicles, our FSW machines are often used to permanently connect sheet metal covers with die-cast components, creating absolutely watertight cooling circuits. These circuits cool the electronic components of the inverters, which convert the direct current from the battery into alternating current needed for the drive motors in an electric vehicle. The design of FSW inverter housings aims to seal the cooling circuit cost-effectively and permanently without screws, while ensuring excellent heat transfer.

The Battery Management System (BMS) is an essential part of an e-mobility system, as it monitors and controls temperatures during the battery charging and discharging process. Since intricate valve systems are integrated into the cooling water circuit for temperature regulation of the battery, drive, and air conditioning, these systems require a compact housing. To permanently seal this housing after the installation of mechatronic components, the die-cast housings are closed using the FSW process.

Electronic motor housings

Friction Stir Welding is employed in the production of stator housings for electric vehicles to manufacture water-cooled electric motors made of aluminum die casting. FSW enables an optimal combination of strength, durability, and heat dissipation to ensure efficiency and performance of electric motors within a compact space.

V-FSWC550 COMPACT

Application for welding: HV inverter, cooling units and heat exchanger

FSW machinery for high-volume production due two separate operating machine tables

V-FSWC1060

Application for welding: Battery housings, cooling units and heat exchanger

FSW machinery for high-volume production with optional automatic pallet change system

V-FSWC2080

Application for welding: electronic motor housings and PHEV battery trays

FSW machinery with high-process reliability and possibility to weld in constrained areas (option for integrating additional axis)

EV / PHEV Battery Trays

Welding battery trays for e-mobility systems is an important production step in order to create crash-resistant and gas- and liquid-tight connections. FSW is the optimum welding technology for this task. In the initial step, the bottom of the battery tray is welded together with several parallel friction stir welding seams made from extruded profiles, with the low distortion facilitating further processing. Subsequently, FSW is used to weld the lid to the frame made of aluminum cast or extruded profiles.

FLATLINE FSWC2318

Application for welding: large battery tray for full EV and PHEV vehicle components

FSW machinery with exceptional rigidity for part loading from front, back and top side of the machine

FLATLINE FSWC2519

Application for welding: large battery tray for full EV and PHEV vehicle components

Table extension for simultaneous part operation (up to 5.500mm in length)

FSW machinery for the achievement of highest welding speeds in reference to the application (up to 5.000mm/min)

valuable insights on FSW processing

How to lid cooling channel electronic

How to clamp device

FSW machine

Flatline machine

How to seal electronic box

Rapid Stir

Rapid Stir Spot Welding (RFSSW)

Angle head

Your Expert for FSW

The leading high-technology company Stirtec is providing assistance in the industrial use of Friction Stir Welding, especially within the automotive (e-mobility), aerospace and other industries. With more than 20 years’ experience in the welding technique, we are successfully guiding through the process of Friction Stir Welding and customer’s applications. Well-known in the automotive market as a FSW full-line supplier, Stirtec is giving its expertise in product development on weldability with the capability of manufacturing first prototypes over to providing most-productive solutions as FSW centers and complete production line including automation.

Find out more about the benefits of using Friction Stir Welding and how the technology can be implemented towards your application.

Find out more about Friction Stir Welding (FSW)

FOR FSW PROTOTYPE PRODUCTION AND MACHINERY
Your contact person: Markus Hahnl

Are you interested in determining the feasibility of a new concept using Friction Stir Welding? Or do you require assistance in choosing the most-sufficient system for serial production for your application?
Please contact us directly - we'll gladly provide guidance and support.

markus.hahnl@stirtec.at

+43 676 60 23 306