Thesis work 30hp- Defining of leakage requirements for battery frames in relation to pack level

Background:

Scania develops and produces high-pressure die-cast (HPDC) aluminium frames for batteries used in electrified powertrains. A key quality parameter is tightness, where the frames must meet certain leakage requirements to ensure function and safety at the pack level.

Today, there is a risk that the requirements at component level (battery frame) are more restrictive than necessary, which can lead to increased manufacturing costs and scrap without adding corresponding value to the system level. At the same time, too permissive requirements can compromise performance and safety at the pack level. The relationship between the leakage from individual battery frames and the total leakage in a fully assembled battery pack is therefore of great importance for optimising the specification of requirements.

Purpose:

The purpose of the thesis work is to:

· Investigate how leakage from individual battery frames affects the overall leakage on pack level.

· Suggest how leakage requirements should be designed at the component level to achieve a balance between function, quality and cost.

Questions:

· How can one mathematically/statistically model the relationship between individual component leakage and the total pack leakage?

· What variations arise in reality and how can these be included in a robust set of requirements?

· How can tolerances be defined that provide sufficient packing density without exaggerating the requirements of individual frames?

· What are the consequences of different levels of requirements in terms of production costs, quality outcomes and risk of rework/scrap?

Method:

· Literature review: Review of existing standards, methods and industry practices for tightness requirements.

· Data Analysis: Collection and analysis of leak test data from the component and pack level.

· Statistical modelling: Building a model that can predict pack leakage based on the contribution of individual components.

· Requirements simulation: Evaluate different levels of component requirements and analyse the effects on pack level.

· Recommendations: Develop proposals for optimized requirements

Education/program/focus:

In the final year of a Master’s program in Mechanical Engineering, Physics, Mathematics or similar program

Number of students: 2 Start date for the thesis work: January, 2026 Estimated time required: 6 months

Contact persons and supervisors: 

Traton Supervisor: Madeleine Renck, madeleine.renck@scania.com Senior Design Engineer, Traton SE AB
Traton Manager: Sofia Nylén, sofia.nylen@scania.com Traton SE AB

Application: Your application must include a CV, personal letter and transcript of grades

A background check might be conducted for this position.