Alternative Materials to the Battery Frames

Sammanfattning

This master’s thesis, conducted within the Machine Design track at KTH Royal Institute of Technology in collaboration with Scania AB, explores alternative materials for battery housings in heavy-duty vehicles. The research focuses on identifying lightweight, cost-effective and high-strength materials to improve the efficiency, durability, and sustainability of Scania battery systems while ensuring compatibility with existing production methods. A literature review and discussions with industry experts identified potential materials, including composites, polymers, and sustainable alternatives. Key performance criteria such as mechanical properties, environmental resistance, and manufacturability were analyzed. Advanced design and simulation techniques assessed materials under various operational conditions, enabling detailed comparisons with current battery housing materials. Material samples were obtained through strategic partnerships with suppliers and underwent rigorous mechanical testing using standardized protocols to assess their strength, structural integrity, and resistance to corrosion and fatigue. The results showed that several alternatives matched or exceeded traditional materials in performance, offering superior strength-to-weight ratios and durability. This research provides Scania AB with actionable insights on adopting sustainable materials in battery housing manufacturing, highlighting the importance of integrating mechanical testing, simulations, and design methodologies.