Comparative Analysis of Aluminium and Carbon Fiber-Reinforced PA6 Composites for Electric Vehicle Battery Housing Applications

Prakash R S; Akash M; Ashiq A; Karthick Raja S; Santhosh Kumar S

doi:10.5935/jetia.v12i61.4339

Authors

Prakash R S Department of Automobile Engineering,Hindusthan College of Engineering and Technology
Akash M Department of Automobile Engineering, Hindusthan college of Engineering and Technology, Coimbatore, Tamil Nadu, India.
Ashiq A Department of Automobile Engineering, Hindusthan college of Engineering and Technology, Coimbatore, Tamil Nadu, India.
Karthick Raja S Department of Automobile Engineering, Hindusthan college of Engineering and Technology, Coimbatore, Tamil Nadu, India.
Santhosh Kumar S Department of Automobile Engineering, Hindusthan college of Engineering and Technology, Coimbatore, Tamil Nadu, India.

DOI:

https://doi.org/10.5935/jetia.v12i61.4339

Abstract

The increasing demand for sustainable and high-performance materials in electric vehicle (EV) applications has led to the exploration of polymer composites as potential alternatives to traditional metal enclosures. This study investigates the mechanical, thermal, electrical, and environmental performance of polyamide 6 (PA6) reinforced with carbon fiber (CF) at 2 wt%, 4 wt%, and 6 wt% as a substitute for aluminium in EV battery housing. A comprehensive experimental evaluation was carried out including Smoke Density Test (ASTM E662), Heat Deflection Temperature (ASTM D648), Surface and Volume Resistivity (ASTM D257), and Water Absorption (ASTM D570). The results reveal that the PA6-CF composites significantly outperform aluminium in multiple critical parameters. Notably, smoke density was drastically reduced with the addition of CF, with 6 wt% showing the lowest optical density, enhancing fire safety. The HDT of the composites improved with increasing CF content, reaching 215 °C at 6 wt%, surpassing the temperature limitations of standard thermoplastics. Surface and volume resistivity measurements demonstrated a tunable range of electrical conductivity suitable for antistatic applications. Moreover, the incorporation of carbon fiber reduced water absorption from 1.8% in unreinforced PA6 to 0.5% in 6 wt% CF composites, offering superior dimensional and hydrothermal stability. Overall, the PA6-carbon fiber composite system not only meets but exceeds aluminium in critical metrics relevant to EV safety and efficiency, while contributing to recyclability, weight reduction, and environmental sustainability. This work underscores the potential of thermoplastic composites in redefining material strategies for advanced EV battery enclosures.

Keywords: Electric Vehicle Battery Enclosure, PA6–Carbon Fiber Composites, Heat Deflection Temperature (HDT), Smoke Density, Surface and Volume Resistivity