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A bodyguard made of steelThe battery housing for e-mobility
Anyone who chooses e-mobility is not simply following a trend, but investing in a sustainable future. Our teams set out to find the best way to protect the heart of the electric vehicle: its battery. The result is the selectrify® battery housing made from ultra-high-strength steel - safe, cost-effective and sustainable.
How steel improves the safety and efficiency of electric vehicles
As part of the selectrify® initiative, thyssenkrupp Steel has developed a steel battery housing that combines key requirements for e-mobility: high levels of safety, lower production costs, an improved carbon footprint and a compact design.
Battery housings protect the heart of the electric vehicle
The battery housing is one of the safety-critical components of an electric vehicle. It protects the sensitive battery modules against mechanical damage, heat, moisture, dirt and corrosion.
In the event of an accident, the structure must be stable enough to absorb severe loads and minimize damage to the battery cells. An integrated cooling system also supports the battery’s thermal management. High corrosion resistance ensures that the housing continues to perform its protective function even when permanently exposed to moisture, road salt and other environmental influences.
Steel improves fire safety in electric vehicles
Damaged lithium-ion batteries can become extremely hot and, in the worst-case scenario, catch fire. A robust battery housing therefore protects not only the battery but also the vehicle’s occupants.
Under extreme heat, aluminum loses its structural stability relatively quickly and can collapse after around 30 seconds in fire tests. Steel has a significantly higher melting point and can retain its structural strength for longer in the event of a battery fire. This provides better protection for the passenger compartment and gives occupants more time to leave the vehicle in an emergency.
Steel battery housings improve the carbon footprint right from the production stage.
Up to two-thirds fewer greenhouse gas emissions
A key challenge for e-mobility is making not only vehicle operation but also production more climate-friendly. As electric vehicles produce no direct CO₂ emissions while driving, greater attention is being paid to the manufacture of the battery and its components.
A life cycle assessment shows that producing a steel battery housing can generate up to two-thirds fewer greenhouse gas emissions than manufacturing a comparable aluminum housing. Steel therefore offers significant potential to reduce the carbon footprint of electric vehicles as early as the production stage.
Up to 50 percent lower production costs
In addition to its carbon footprint benefits, steel offers clear economic advantages. A cost analysis based on annual production of 200,000 vehicles over a seven-year period takes into account factors including material and manufacturing costs, component production, body-in-white production, leak testing and corrosion protection.
The result: At a comparable weight, steel battery housings can be manufactured at up to 50 percent lower cost than aluminum versions. Material costs are a key factor, as aluminum can cost around three times as much as steel, depending on the design.
Compact design creates space for greater range
Ultra-high-strength steels combine high structural strength with reduced material thickness. This makes it possible to design thin-walled, lightweight and compact battery housings that require less installation space in the vehicle.
The additional space can be used for larger battery modules. Greater battery capacity enables a longer driving range and can help alleviate potential buyers’ concerns about limited range and insufficient charging infrastructure.
Compact battery housings made of high-strength steel create space for larger batteries and greater range.
A future-ready solution for e-mobility
The selectrify® steel battery housing helps automotive manufacturers combine safety, cost-effectiveness and sustainability. Its flexible design, high level of durability and potential to accommodate larger batteries make steel a high-performance material for future electric vehicles.
The solution can therefore help make electric vehicles safer, more cost-efficient and more suitable for everyday use - while also reducing CO₂ emissions across the production chain.