As the demand for electric vehicles increases, the stability of batteries has become one of the most significant issues. The battery housing, which protects the battery from external stimuli such as vibration, shock, and heat, is the crucial element in resolving safety problems. Conventional metal battery housings are being converted into polymer composites due to their lightweight and improved corrosion resistance to moisture. The transition to polymer composites requires high mechanical strength, electrical insulation, and thermal stability. In this paper, we proposes a high-strength nanocomposite made by infiltrating epoxy into a 3D aligned h-BN structure. The developed 3D aligned h-BN/epoxy composite not only exhibits a high compressive strength (108 MPa) but also demonstrates excellent electrical insulation and thermal stability, with a stable electrical resistivity at 200 °C and a low thermal expansion coefficient (11.46×ppm/°C), respectively.

In this study, the deformation of friction stir welding on the aluminum battery housing material(AL6063-T5) applied to the electric vehicle was effectively predicted through experiments and numerical simulations. The temperature data were measured during the friction stir welding experiment, and the numerical simulation was carried out using the experimental temperature data. In the heat transfer analysis, the temperature distribution of the structure over time was calculated using the Reynolds equation. The final friction stir welding deformation was calculated by performing the structural analysis using the calculated temperature distribution data over time. The thermal elasto-plastic analysis was performed according to the friction stir welding process conditions and the welding sequences. Finally, the optimum welding condition was derived that the welding speed is 1000 mm/min and the rotation speed of the tool is 2000 RPM.