The transition toward sustainable electric mobility has accelerated the demand for advanced lightweight materials that can enhance electric vehicle (EV) performance while maintaining structural integrity and energy efficiency. This study investigates the mechanical, thermal, and aerodynamic properties of key lightweight materials—Aluminum Alloy (6061-T6), Magnesium Alloy (AZ91D), Carbon Fiber Composite, Glass Fiber Reinforced Polymer (GFRP), and Titanium Alloy (Ti-6Al-4V)—through experimental testing, simulations, and industry-based validation. Tensile, fatigue, and impact tests were performed under ASTM and ISO standards, while computational analyses provided insights into crashworthiness, aerodynamic drag, and battery cooling efficiency. Among the materials tested, Carbon Fiber Composite exhibited superior tensile and fatigue strength, while Magnesium Alloy (AZ91D) provided the lowest density, significantly reducing overall vehicle weight. Aluminum Alloy (6061-T6) demonstrated excellent thermal conductivity, making it ideal for battery enclosures, and Titanium Alloy (Ti-6Al-4V) showed exceptional impact resistance. The findings provide a comparative framework for selecting optimal materials for different EV components, aiming to guide automakers in developing safer, more efficient, and sustainable electric vehicles.
Electric Vehicles, Lightweight Materials, Aluminium Alloy, Carbon Fiber Composite, Energy Efficiency, Thermal Management, Structural Integrity, Material Sustainability, Manufacturing Optimization, Automotive Engineering
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