On the Substitution of Aluminium for Copper Conductors in Battery Systems
Doctoral thesis
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https://hdl.handle.net/11250/3121364Utgivelsesdato
2024Metadata
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Sammendrag
Aluminium’s electrical conductance per-unit mass and per-unit cost is unequalled. These are two desirable properties in a world undergoing widespread electrification. Electricity generation, transmission and utilisation is fundamental in transitioning from non-renewable energy sources and is placing greater demand for low-cost electrical conductors.
Alas, aluminium’s properties are not all favourable to electrical applications, so copper has risen as the dominant conductor material in all but high-voltage long-distance power transmission. Successfully developing aluminium conductors in new applications requires overcoming several challenges, from technical limitations in material properties and manufacturing processes, to programmatic obstacles in development scope and organisation.
This thesis explores the implementation of aluminium conductors in battery system applications. The thesis starts from a broad perspective of material substitution innovation before focusing down on specific technical bottlenecks. The thesis includes analysis of literature, interviews with experienced project managers, reliability testing of design solutions and evaluation of a new manufacturing process. The contributions presented include: a framework for categorising material substitution product development barriers, a test methodology for comparison of detachable aluminium contacts in battery system applications, reliability evidence for specific detachable aluminium contact configurations, a new metric for evaluating the electrical resistance of bimetallic welds and the first electrical assessment of a novel bimetallic joining process. In doing so the thesis supports the development of aluminium conductors and the substitution from copper conductors.
Består av
Paper 1: Elkjær, Aksel Sean; Ringen, Geir. Barriers and Enablers for Material Substitution Innovations: Positioning Exploration and Exploitation Learning Processes. This paper is submitted for publication and is therefore not included.Paper 2: Elkjær, Aksel Sean; Ringen, Geir; Bjørge, Ruben; Hagen, Catalina Hoem Musinoi; Lædre, Sigrid; Magnusson, Niklas. Reliability of Bolted Aluminum Busbars for Battery Systems: Effect of Nickel Coating and Corrosive Environment. IEEE Transactions on Transportation Electrification 2022 ;Volum 9.(1) s. 1060-1071. Copyright © 2022 IEEE. Available at: http://dx.doi.org/10.1109/TTE.2022.3196309
Paper 3: Elkjær, Aksel Sean; Sørhaug, Jørgen A; Ringen, Geir; Bjørge, Ruben; Grong, Øystein. Electrical and thermal stability of Al-Cu welds: Performance benchmarking of the hybrid metal extrusion and bonding process. Journal of Manufacturing Processes 2022 ;Volum 79. s. 626-638. Published by Elsevier Ltd on behalf of The Society of Manufacturing Engineers. This is an open access article under the CC BY license. Available at: http://dx.doi.org/10.1016/j.jmapro.2022.04.029
Paper 4: Elkjær, Aksel Sean; Ringen, Geir; Haskins, Cecilia. A Literature Review of the Integration of Test Activities into the Product Development Process Conferences on Systems Engineering Research, Recent trends and advances in Model Bases Systems Engineering, Springer 2022. © The Author(s), under exclusive license to Springer Nature Switzerland AG 2022. Available at: https://doi.org/10.1007/978-3-030-82083-1_21