Grant: Alliance Grants

This research partnership aims to integrate lightweight fiber-reinforced plastic (FRP) composite materials into battery enclosures and protective panels of next-generation electric vehicles (EVs). Owing to the immense mass of the battery cells and fortified suspension systems, current EVs are substantially heavier than gasoline-powered vehicles. A significant reduction in the mass of vehicle structures through use of FRP composites will drastically improve the performance of vehicles and extend their driving range from a single charge while concurrently improving their crash safety, addressing a major innovation challenge. Characterizing and modelling the directional- and strain rate-dependent deformation response and fracture behaviour of FRP composites, which is required for energy absorbing structures in EVs, is complex. The proposed research will address a critical need to accelerate the constitutive characterization and model calibration process for FRP composites using robust artificial intelligence (AI)-supported virtual tools. Several key scientific challenges will be addressed through the proposed research, including generating a unique characterization data set for two FRP composite materials, developing advanced high-fidelity analytical tools to predict material performance, and producing a novel AI-based material constitutive model to accelerate analysis of structures and capture material variability. The research outcomes will contribute to substantial weight reduction of EVs with significantly improved driving range, resulting in greater adoption and consequently a positive environmental impact from reduced sectorial greenhouse gas emissions. EV structures that are optimized to absorb maximum energy during a crash will greatly enhance occupant safety and improve battery protection from damage and fire hazards, thus, reducing crash fatalities. The research outcomes will be adopted by the Canadian-based operations of the auto sector partner, GM, and utilized to rapidly develop next-generation lightweight EV structures; thus, gaining an innovation-based competitive advantage by accelerating the rate of made-in-Canada products to the global market.