Battery Casing Products And Services

With our market and technology know-how, simulation methods, cost and CO₂ footprint analysis and testing capacities, we provide consulting and development for your materials, products and technologies.

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Thermal Runaway Testing for Battery Casings*

AZL Joint Partner Project | Open to Join

Benchmarking Systems for high-gradient heating and hot particle blasting for fire testing of housing and functional materials for EV battery casings

Battery Casings for electrical vehicles, both for ground and air transportation, offer huge economical potential. All kinds of materials, steel, aluminum and composites are used to manufacture components of the battery casings. For all components, independent if used in the surrounding box/lid structure or as functional elements within the casing, the characterstic behaviour under thermal runaway conditions are essential criteria to test and to comply with legal and OEM-standards. AZL is renown for developing and operating test setups to provide evidence on the suitability of materials for application in battery casings.

What will you get?

Joint definition of test scenarios of relevance available at the market and expert assesment of testing results by implementation and comparison. Opportunity to co-define requirements for improving test procedures to further increase representativity for real thermal runaway events including testing results of your materials and comparison with other materials.

WP1: Analysis of currently available test setups, providers and knowledge regarding testing of materials for structural and non-structural components of battery casings
WP2: Implementation of relevant test setups of interest and benchmarking of test results.
WP3: Development and implementation of improved systems for high-gradient heating and hot particle blasting

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bitte beachten Sie, dass alle Projektinformationen aufgrund der Internationalität der Projekte nur auf Englisch zur Verfügung stehen.

*bitte beachten Sie, dass alle Projektinformationen aufgrund der Internationalität der Projekte nur auf Englisch zur Verfügung stehen.

Application Relevant Fire Test Procedure for Battery Pack Protection

AZL Engineering Service

Material Strength Test

3 different temperatures: 800°C, 1000°C, 1200°C
During exposure to fire: tensile force of 0.5 kN over 10 minutes
If no failure, increase force up to 5 kN

Particle Blast Test

Equal damage effect of thermal runaway with real battery cell
Exposure to 1200°C for 80 seconds
Afterwards 10 seconds blast duration, filling mass 450 g

Test specimen size for both tests is 200 mm x 100 mm, flame exposure along the full specimen width Approx. 10 test specimens required, 2 for each tests and temperature

AZL’s Expertise

AZL Joint Partner Project completed in 2022:

Fire Protection – Application Relevant Fire Test Procedure for Composites

Consortium of 24 industrial partners along the complete value chain
Setup of test procedure and test bench with 3 different temperatures measuring the material strength under fire load
50+ materials tested and compared
Impact on performance, weight and cost

To learn more about fire safety for electric vehicles, take a look @ Ravi’s presentation „Application-relevant test methods for characterising materials under thermal-runaway conditions.“ from the AMI Fire Resistance Conference. ⏬ Download

Application Relevant Bottom Impact Protection for Battery Casing

AZL Engineering Service

Simulates oblique angle impact occurring in high-speed driving over hard objects
3 different angles for impact possible: 90°, 45° and 25°
15 mm dart impactor, max. height 4 m, max. mass 60 kg
Large-scale tests and small-scale tests (only 90°)

Test specimen size for large-scale 400 mm x 400 mm, small-scale 120 mm x 120 mm. Approx. 2 specimens for each angle in large-scale test, 10 specimens for small-scale test.

AZL’s Expertise

AZL Joint Partner Project completed in 2022:

Application-relevant test method and investigation of the relative safety performance of different material options for bottom impact protection battery casings

Consortium of 13 industrial partners along the complete value chain
Improvement of an existing test bench* for 25° oblique impact and setup of test procedure
20+ materials tested and compared
Impact on performance, weight and cost

*Original test bench developed by Thyssenkrupp

EV Battery Casings Consultancy

AZL Engineering Service

Together we analyse the fast-growing market for EV battery casings and identify opportunities for your materials, products and technologies considerung cost, weight and environmental impact Our Assets related to Battery Casings AZL conducted several consortium projects with 76 industrial companies along the complete value chain, investigating:

Worldwide standards, regulations and specifications
60+ state of the art casings and future concepts
About 30 different multi-material design concepts, including future cell-to-pack designs
- Alternative cell-packing and cooling options for future cell-to-pack designs
- Analysis of Alternative materials to mitigate thermal runaway propagation
- Analysis of and design for recycling
CEA analysis and optimisation to crash and intrsuion load cases
Modelling production chains and benchmarking analysis of weight, cost and CO2 footprint, and volumentric efficiency
Experimental testing of high speed oblique foreign object impact protection, more than 25 different materials
CAE design relevant fire safety testing, more than 50 different materials and protection layers