Why Use Aluminum for Charging Stations and Other Electrical Components

2024-08-16T18:22:27+00:00August 15th, 2024|

The text, “Why Use Aluminum for Charging Stations” is printed on a photograph of an electrical vehicle charging station with a blurred city skyline background. The Taber logo is under the wording.

With electrical vehicles (EVs) expected to make up 50% of new car sales by 2030, billions in funding has been set to create a network of charging stations. As the demand for EV infrastructure grows, selecting the right materials for these stations becomes crucial. This raises a key question: why should aluminum for charging stations be the material of choice?

Let the leading aluminum extruder, Taber Extrusions, guide you through the key advantages of using aluminum for charging stations. We’ll delve into the common aluminum alloy series employed in these applications and examine its role in other aluminum components within the realms of electrical power transmission and electronics.

Key Advantages of Using Aluminum for Charging Stations

  1. Reduce cost of post-process expenses

Aluminum extrusions can be designed to incorporate aluminum components such as heat sinks, screw ports, grooves for mounting components, integrated hinges, or combining pieces to slide parts together.

In doing so, it removes the need for additional post-process activities like milling and welding, speeding up assembly and reducing costs. Also, due to the soft nature of aluminum, any products needing milling are easier to mill than most other material choices.

  1. Thermal conductivity

Efficient thermal management is essential for electrical components. Aluminum’s high thermal conductivity helps dissipate heat effectively, preventing overheating and enhancing the performance and safety of charging stations.

  1. Corrosion resistance

Aluminum is known for its corrosion-resistant properties, which is crucial for charging stations exposed to harsh environmental conditions, ensuring longevity and reliability. Additionally, it does not require coating for rust control, creating more cost savings and lower maintenance costs.

  1. Cost-effective material option

Aluminum’s low melting point makes it more affordable, since it requires less energy to melt which reduces energy costs. It heats and cools quickly, speeding up production and lowering labor costs.

  1. Lower transportation costs

Aluminum’s lightweight nature makes it an excellent choice for EV charging stations, which often need to be installed in various locations including remote and urban areas. The reduced weight lowers transportation and installation costs without compromising strength.

  1. Recyclability

Aluminum is 100% recyclable, aligning with the sustainability goals of the EV industry. Using aluminum in charging stations supports a circular economy, reducing the environmental impact of manufacturing processes.

A graphic entitled “Advantages of Using Aluminum for Charging Stations” depicting the benefits, which include an icon of a welder with text “reduces post-process expenses,” a recycle symbol with the text “100% recyclability,” a hand holding a dollar sign with text “cost-effective material,” a thermometer next to text “thermal conductivity,” an icon of missing pieces of a water drop shape with “corrosion resistant,” an 18-wheeler with “lower transportation costs.”

Common Aluminum Alloy Series Used for Charging Stations

Different applications within EV charging stations require specific aluminum alloys to meet varying demands. The most used aluminum alloy series include:

This aluminum alloy is heat treatable and weldable. Known for its high levels of corrosion resistance, strength, and flexibility, these alloys are widely used in infrastructure projects. Using the 6XXX series aluminum in charging infrastructures would be an ideal option, as well as for items like the battery housing, motor housing or power station components.

  • 5000 Series Aluminum (hard alloy):

These alloys offer higher strength and weldability; as well as excellent corrosion resistance especially in marine environments, making them suitable for both structural and electrical applications.

Pure aluminum (99% or higher) is used in electrical applications where superior heat and electrical conductivity is required. It is commonly found in electrical transformers and power grids. An excellent choice for busbars in the e-charging stations.

A graphic entitled “Aluminum Series & Functionality” with a design plan for an e-charging station with the word “infrastructure” on top of it and “6000 Series Aluminum” below it, a photo of electrical components for a charging station with the words “Electrical Conductivity” on top of it and “1000 Series Aluminum” below it, a photo of two e-charging stations at the beach with the words “Marine Environments” on top of it and “5000 Series Aluminum” below it.

Aluminum in Other Electrical Components (electrical / power transmission and electronics)

Beyond EV charging stations, aluminum plays a critical role in various electrical components, particularly in electrical / power transmission and electronics:

  • Cables and conductors: Aluminum is extensively used in electrical cables and conductors due to its high conductivity and cost-effectiveness.
  • Heat sinks and enclosures: In electronics, aluminum’s excellent thermal conductivity makes it ideal for heat sinks and enclosures, helping to manage heat dissipation effectively.
  • Busbars: Aluminum busbars are favored in power distribution systems for their superior electrical conductivity and lightweight properties.

Choosing aluminum for charging stations and other electrical components is a strategic choice driven by cost-effectiveness and intrinsic material properties. This selection accelerates production and installation, prolongs product lifespan, and meets essential functional requirements.

Taber Extrusions Takes the Lead in Incorporating Aluminum for Charging Stations

As the EV market grows, aluminum will be pivotal in developing efficient, durable, and sustainable charging networks. And who is better suited to take the lead than the leading aluminum extruder, Taber Extrusions? This leading aluminum extrusion company specializes in making aluminum alloys and aluminum components such as motor housing, heat sinks, and other power station components integral for electric vehicle charging stations.

Leading the Way in Extrusion with Precision Engineering and Quality Assurance

Taber comes with a team with vast experience in advanced equipment for extruding aluminum components such as SolidWorks (CAD design) and CAD Software (Auto CAD). To ensure topnotch quality assurance, Taber is certified and approved by several international and industry standards:

  • ISO 9001:2008 (Technically equivalent to EN9100:2009 and JISQ 9100:2009)
  • AS 9100C
  • ABS QUALITY ASSURANCE Program certificate no. 11-MMPQA-652. ABS Mill approval to produce extruded aluminum alloys Products for Marine applications 5083H111, 5086H111, 5454H111, 5456H111, 6061T6, 6082T6. Maximum diameter: 1.0-inch Casting process included.

About Taber Extrusions

Taber Extrusions is your premier full-service partner unwaveringly committed to consistently meeting and surpassing customer expectations. We deliver products and services of the highest quality, a testament to our dedication to excellence. This steadfast commitment forms the core of our value-added philosophy, ensuring that we provide exceptional value and superior performance in every aspect of our business.

Contact Taber Extrusions to get a quote or connect with our team at 1-888-984-3795.

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