Product Advantage
Weight Reduction & Energy Savings: With aluminum’s density 67% lower than steel, these extrusion components reduce vehicle curb weight by 25-35%. For a mid-size EV (e.g., 1800kg curb weight), this translates to a 12-18% longer battery range (adding 70-110km to a 600km-range model) and cuts annual charging costs by 10-15%. For ICE vehicles, it lowers fuel consumption by 5-8L per 100km.
Enhanced Structural Safety: 6061-T6 aluminum’s yield strength (≥241MPa) and 7005-T6’s impact resistance (≥15kJ/m²) ensure excellent crash performance. Multi-cavity bumper beams, for example, absorb 30% more impact energy than steel beams, meeting EU NCAP and US FMVSS 301 crash standards. Floor crossmembers also improve vehicle torsional rigidity by 20%, reducing body roll during sharp turns.
Superior Corrosion Resistance: The surface undergoes two protective treatments—acid pickling (to remove oxide layers) and electrostatic powder coating (70-90μm thickness)—withstanding 1200 hours of neutral salt spray testing (ASTM B117). This prevents rust in coastal or snowy regions, keeping components durable for 12-15 years.
Design Versatility & Assembly Efficiency: Precision extrusion enables complex profiles, such as hollow battery frame rails with integrated cable channels (reducing 15% of wiring assembly time) and variable-wall bumper beams (thicker at stress points, thinner elsewhere for weight optimization). CNC drilling (tolerance ±0.03mm) pre-cuts mounting holes, shortening vehicle assembly time by 25%.
Eco-Friendly & Cost-Effective: 100% recyclable aluminum aligns with automotive sustainability goals—recycling uses 95% less energy than primary aluminum production. High-volume extrusion (output up to 550m/h) lowers unit costs by 15% compared to aluminum forging, making it suitable for mass-produced vehicles.
Technical Parameters
Parameter | Specification | Unit | Test Standard |
Material | 6061-T6, 7005-T6 Aluminum Alloy | - | ASTM B221 |
Tensile Strength (6061-T6) | ≥276 | MPa | ASTM B557 |
Tensile Strength (7005-T6) | ≥310 | MPa | ASTM B557 |
Yield Strength (6061-T6) | ≥241 | MPa | ASTM B557 |
Yield Strength (7005-T6) | ≥276 | MPa | ASTM B557 |
Density | 2.7 | g/cm³ | ASTM B328 |
Extrusion Profile Type | Single-Cavity / Multi-Cavity / Variable-Wall (Customizable) | - | Customer Requirement |
Dimensional Range (Customizable) | Length: 800-6000; Width: 30-400; Height: 15-250 | mm | GB/T 6892 |
Machining Tolerance | ±0.03 | mm | ISO 2768-1 |
Surface Treatment | Acid Pickling + Electrostatic Powder Coating (70-90μm) | - | ASTM B981 |
Corrosion Resistance | ≥1200 | Hours (Neutral Salt Spray Test) | ASTM B117 |
Impact Strength (23℃) | ≥15 | kJ/m² | ASTM E23 |
Elongation at Break | ≥12 | % | ASTM B557 |
Applicable Vehicle Scope | Passenger Cars, EVs, Light Commercial Vehicles | - | IATF 16949 |
Product Uses
1. EV Battery Frame Rails: Multi-cavity 6061-T6 aluminum extrusion rails form the core of EV battery enclosures, with a load-bearing capacity of 600-900kg. The integrated cavity design houses battery cooling pipes, reducing assembly steps by 20% and protecting batteries from impact—critical for preventing thermal runaway.
2. Automotive Bumper Beams: 7005-T6 aluminum extrusion front/rear bumper beams (cross-section: 120×80mm multi-cavity) absorb crash energy during low-speed collisions (≤15km/h) without permanent deformation, meeting insurance industry repair cost standards. Their lightweight design cuts bumper weight by 40% vs. steel.
3. Floor Crossmembers: 6061-T6 variable-wall floor crossmembers (thickness 2.5-4mm) reinforce the vehicle floor, supporting passenger and cargo loads (up to 500kg) while reducing floor weight by 30%. They are widely used in compact EVs and family sedans.
4. Light Commercial Vehicle Parts: Solid 7005-T6 aluminum extrusion side rails for vans and pickup trucks withstand heavy payloads (1000-1500kg) and resist corrosion from road salt. They reduce vehicle weight by 25%, lowering fuel consumption by 6-9L per 100km for diesel-powered commercial vehicles.
Product Operate Guide
Pre-Installation Check: Verify component dimensions (length, profile) against vehicle blueprints. Use a wire brush to clean extrusion surfaces—remove any residual oxide debris to ensure strong welding/bonding.
Installation Steps: For battery frame rails, use M10-M12 torque bolts (tightening torque 30-40N·m) to fasten to the chassis. For bumper beams, use aluminum spot welding (weld point diameter ≥5mm) or structural adhesive (shear strength ≥15MPa) to attach to the vehicle body.
Post-Installation Validation: Use a coordinate measuring machine (CMM) to confirm component position (tolerance ≤0.3mm). Conduct a static load test (apply 1.1× rated load) to ensure no deformation or looseness.
Maintenance Tips: For daily use, clean components with neutral detergent to remove road grime. For commercial vehicles, inspect powder coating every 3 months—repair scratches with automotive-grade aluminum touch-up paint.
FAQ
1. Q: Can these components withstand high temperatures (e.g., 80℃ in engine bays)?
A: Yes. 6061-T6 and 7005-T6 alloys retain 85% of their strength at 80℃. We also offer heat-resistant powder coating (up to 120℃) for engine bay parts, with a lead time of 5-8 working days.
2. Q: What’s the MOQ for customized extrusion profiles?
A: Standard profiles (e.g., single-cavity bumper beams) have an MOQ of 300 pieces. Custom profiles (e.g., unique multi-cavity rails) require an MOQ of 1500 pieces, and we waive die costs for orders over 10,000 pieces.
3. Q: How to prevent aluminum-steel contact corrosion?
A: Use non-conductive gaskets (silicone or PTFE) between aluminum and steel parts, and apply anti-corrosion sealant to joints. We also supply zinc-plated fasteners (corrosion resistance ≥800 hours salt spray) for added protection.
4. Q: What warranty do you provide?
A: We offer a 8-year warranty for material defects (cracking, premature corrosion) and manufacturing errors. For automotive OEMs, we provide free technical support for assembly issues during the warranty period.
