Aluminium Alloys For Lithium-ion Battery Casing Materials

Ideal materials for Lithium-ion Battery Case
Aluminium Alloys with High Strength & reduce weight & one-time deep drawing
Custom Solution for your battery housing design
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With the core technology and robust supply chain advantage in the field of battery foil, HD METAL is equipped to supply high-strength aluminium sheet materials to manufacturers of lithium-ion battery housing materials, meeting the unique needs of many customers for aluminium material solutions.
Based on the current applications of different lithium-ion batteries in various fields, we have developed aluminum alloy sheets suitable for cylindrical, prismatic, and pouch-shaped lithium-ion battery cases, which are very friendly to various deep-drawing processes. The aluminum alloys supplied by HD Metal combine the high strength of the material and excellent laser weldability and help you achieve the ultimate casing material’s ultimate thinning.

Aluminium Sheet for Square Battery Case

The battery is one of the core components of new energy electric vehicles, and a good housing material determines the safety and life of the storm. The aluminum housing material supplied by HD Metal is easy to form, resistant to high-temperature corrosion, has good heat transfer and electrical conductivity, and perfectly matches the laser sealing process for square battery cases.
The aluminum power battery case of 3003 aluminum alloy can be drawn and formed at one time, which can eliminate the welding process at the bottom of the subject compared with the stainless steel case.
Therefore, it is essential to choose a high-quality aluminum battery case material and select the optimal encapsulation process according to the characteristics of the case material. It is significant for the safety and service life of the battery. The current electric vehicle aluminum battery housing generally uses 3003 aluminum sheet.
· Alloy: 1050 / 3003
· Temper: O / H14
· Thickness: 0.30 – 0.80mm
· Width: 200 – 1650mm

Aluminium Circle Plate For Cylindrical Battery Case

· Alloy: 1050 / 1060 / 3003
· Temper: O / H14 / H24
· Thickness: 0.30 – 0.80mm
· Width: 80 – 400mm
Mechanical & Material properties



Mechanical propertiesAlloy

Material properties (within same temper)


Tensile strength

Yield strength


Bulging resistance

Creep resistance

Square tube formability

Laser weldabilitySquare tube formability










Excellent balance of properties














Al–Mn alloy materials














Pure-aluminum materials





Why Use HD METAL Aluminium alloys for Battery Housing Cases

High strength, high precision aluminum alloy material.
Lighter than steel shells to achieve the weight reduction requirements of EV.
It can be deep-drawn once, with excellent laser welding, which improves the efficiency of battery case production.
Excellent anti-collision and anti-explosion performance to enhance battery safety.

Battery Housing Design

Lithium-ion batteries are characterized by high energy density, long cycle life, wide operating range, and safety and reliability, catering to the rapid development of energy storage technology. HD Metal works closely with our customers to provide battery housing solutions that match the needs of lithium batteries in different areas.

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Exploring More Information About Lithium-ion Battery Shell Materials

What is aluminum shell lithium battery?

Aluminum shell lithium battery is a battery shell made from aluminum alloy material. The aluminum shell battery is a hard shell in terms of appearance, mainly used in square and cylindrical cells.

Lithium battery packs use aluminum shell packaging because they are lightweight and safer than steel shells. Aluminum shell lithium battery is the mainstream of the current liquid lithium battery and is used in almost all areas involved in lithium batteries.

Aluminum cases are about 50% lighter than similar steel designs, which is especially important for electric vehicles (this is important for vehicles with all types of engines, but not many people are "mileage anxious" enough to have an internal combustion engine under the hood of their vehicle). The reduction in mass of the aluminum housing has been calculated to increase the range of an EV by 6%-10% compared to alternative structures.

Why use aluminum as the housing material for lithium batteries?

The lithium battery shell design has square corners and rounded corners. The aluminum shell material is generally aluminum-manganese alloy, which contains the main alloy components such as Mn, Cu, Mg, Si, Fe, etc. These five alloys play different roles, such as Cu and Mg, to improve strength and hardness, Mn improves corrosion resistance, and Si can enhance the heat treatment effect of an aluminum alloy containing magnesium. And Fe can improve high-temperature strength.

From the worst result, even if the battery is in case of explosion, the lithium battery aluminum case is much weaker than the bursting force of the steel case, thus causing less harm.

Which is better? Lithium-ion battery with aluminum alloy or lithium-ion battery with steel?

Lithium-ion battery shell material generally has two types of aluminum and steel, this material made out of lithium-ion battery shell has its characteristics, so which one is better?

·  Aluminium battery case

The aluminum shell material is generally 3xxx series aluminum manganese alloy containing essential components such as Mn, Cu, Mg, Si, Fe, etc. These five alloys play different use in the lithium-ion battery aluminum shell, such as Cu and Mg, to improve strength and hardness. Si can enhance the heat treatment effect of an aluminum alloy containing magnesium to improve corrosion resistance, and Fe can improve high-temperature strength.

The lithium-ion battery with the same capacity is lighter than the steel case because the aluminum case can be made thinner.

From the working mechanism of lithium-ion batteries, lithium ions are de-embedded during charging, and the volume of the positive electrode expands; lithium ions are embedded from the positive electrode during discharge, and the negative electrode expands; both will lead to the expansion of the entity, and appropriate ratios of aluminum alloy elements can reduce the bulge factor.

·  Steel battery case

Battery steel shells have specific anti-corrosion properties and high-temperature resistance characteristics. These on the use of steel shell products also significantly impact the user. In the use of steel shell products in the process, if the product's corrosion resistance is not high or the high-temperature environment is not resistant will reduce the application of steel shell products.

Lithium-ion battery steel case defects

Battery steel shell defects are multifaceted: some are caused by raw material surface and internal defects, stamping processing, and material surface quality by the factory finished products, as well as by the intermediate processing distribution links, storage, and use conditions.

1. Drawing

The steel shell presents one or more through the entire steel shell of the naked eye visible line defects.

2. Scuffing

The lithium-ion battery steel case presents irregular openings. This abrasion defect is caused by the surface abrasion of the battery steel strip, which can be found in the corresponding steel strip surface abrasion marks. The degree of distinction can be divided into shallow bruises and deep scratches. Among them, deep scratches sometimes lead to the phenomenon of battery case cracking, and this defect will often be judged as a sanding defect.

3. Point-like pits

The steel case presents irregular-shaped point-like pits, often misjudged as a sanding defect.

4. Gritty eyes

In the production process of using battery shell steel, the typical defect is a sand eye defect. Reasons for the appearance of trachoma can be divided into steel surface defects, steel inclusions, user mold maintenance, and post-process nickel plating.

Aluminium battery housing cases are better than steel cases for lithium-ion batteries.

However, the price of aluminium shell is slightly higher than the cost of steel shell, abundant resources, large construction scale, advanced technology, small environmental impact, energy saving and emission reduction, and increased profitability. However, the steel shell has superior performance and high impact resistance. It will still dominate the market in the future from the market, technical, economic, engineering, and other perspectives of research and analysis.