In the existing automobile manufacturing process, metal inert gas (MIG) and tungsten inert gas (TIG) welding are mainly used. These welding methods are fusion welding, and the heat input in the welding area is very high. Therefore, the deformation of the base material is large, and the residual stress in the vicinity of the welded area is high, resulting in the problem of reduced mechanical strength. In this study, friction stir welding (FSW) was applied to the welding process of the structure constituting the battery frame of a newly developing electric vehicle to compensate for this problem. The welded part is the fillet joint of the side frame and the bottom frame, and experiments and numerical analysis were performed on the welding deformation and residual stress of the full frame structure. A specially manufactured angle head was used for friction stir welding of the fillet joint of extruded type aluminum, not the existing solid type. The optimum process was derived through experiments, and the temperature of the welding center was derived through test correlation between the value of measured temperature and the finite element model. The final deformation result was verified by comparing it with the measured value using a dial indicator. It is expected that the proposed thermal elasto-plastic analysis method will reduce the testing period and the cost of the manufacturing process and increase productivity.

Thermal runaway (TR) in lithium-ion batteries presents a significant safety hazard for electric vehicles (EVs), often resulting in fire or explosion. Mitigating TR requires thermal-protection strategies capable of delaying or suppressing heat propagation within battery pack cases (BPCs). This study proposes a flame-retardant BPC design and evaluates its effectiveness through a combined approach using CFD-based thermal analysis and multiscale experimental validation. In the CFD model, a heat-source temperature of 1107 °C was applied to simulate the thermal load during TR, together with a coolant flow rate of 17 L/min. Material-level verification was conducted through high temperature specimen tests, in which flame-retardant pads were heated to a target of 1100 °C with an allowable tolerance of ±10% for 5 min; the unheated (backside) temperature remained below 160 °C. Full-scale assessment involved heating the BPC upper case at temperatures exceeding 500 °C for 10 min, where the backside temperature remained below 150 °C. Module-level TR experiments further confirmed that the flame-retardant layer reduced the external temperature from 240–260 °C to below 150 °C. The results demonstrate that the proposed design effectively delays thermal penetration and maintains external safety thresholds, offering practical guidelines for developing safer EV battery systems.

Electric vehicle (EV) battery pack cases (BPCs) must withstand mechanical loads such as impact, compression, and vibration to ensure structural integrity and passenger safety. This study evaluates the mechanical durability of a full-scale aluminum BPC using combined experimental testing and finite element analysis (FEA). A bottom impact test, 200 kN compression test, and power spectral density (PSD)-based random vibration test were conducted to simulate representative operating and handling conditions. The numerical model replicated boundary conditions and load profiles identical to the experiments, enabling a direct comparison of stress distribution and deformation characteristics. The results demonstrated that stress and displacement trends predicted by FEA closely matched experimental observations, with stress concentrations appearing at corner and frame junction regions and less than 1 mm deformation recorded under peak compression loading. Vibration responses were most pronounced in the vertical direction, without bolt loosening or structural damage. These results verify the reliability of the proposed BPC design and provide quantitative evidence supporting simulation-driven lightweight battery enclosure development.

The fire resistance and thermal propagation delay of a flame-retardant battery pack case (BPC) were investigated in this study for electric vehicles. Following the Lithium-ion traction battery pack and system for electric vehicles, Part 3: Safety requirements and test methods 31467.3-2015 standards, the BPC specimen was exposed to 500–600 °C for 15 min. Six thermocouples monitored the non-exposed surface, which reached a maximum of 149.7 °C, below the 150 °C limit. No flame occurred during or after heating, and the structure maintained integrity without cracks. The results confirm the flame-retardant BPC’s excellent thermal shielding and demonstrate its potential to enhance EV battery safety by delaying heat transfer and preventing secondary ignition.