AluVolt-G™: Scalable Shear-Assisted Solid-State Extrusion of Graphene-Reinforced Aluminum Busbars for 800V Electric Vehicles

Preprint presenting AluVolt-G™, a solid-state graphene-reinforced aluminum composite busbar engineered via Shear-Assisted Processing and Extrusion (ShAPE) at 450°C. Delivers 88.5% IACS, 98.2% torque retention, 29.6 kg weight reduction per EV, $326.5M annual OEM savings, and 272.5 kg CO2-eq avoided per car. Includes full manufacturing parameters, benchtop protocols, and forensic IP verification.

Authors

Publication Details

Journal
Zenodo (CERN European Organization for Nuclear Research)
Published
2026-11-06
DOI
https://doi.org/10.5281/zenodo.24019800
Primary Topic
Aluminum Alloys Composites Properties
Type
preprint
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preprint

AluVolt-G™: Scalable Shear-Assisted Solid-State Extrusion of Graphene-Reinforced Aluminum Busbars for 800V Electric Vehicles

Antigravity Advanced Materials Laboratory
Zenodo (CERN European Organization for Nuclear Research)
Aluminum Alloys Composites Properties
preprint

AluVolt-G™: Scalable Shear-Assisted Solid-State Extrusion of Graphene-Reinforced Aluminum Busbars for 800V Electric Vehicles

Antigravity Advanced Materials Laboratory
preprint en

Abstract

Preprint presenting AluVolt-G™, a solid-state graphene-reinforced aluminum composite busbar engineered via Shear-Assisted Processing and Extrusion (ShAPE) at 450°C. Delivers 88.5% IACS, 98.2% torque retention, 29.6 kg weight reduction per EV, $326.5M annual OEM savings, and 272.5 kg CO2-eq avoided per car. Includes full manufacturing parameters, benchtop protocols, and forensic IP verification.

Zenodo (CERN European Organization for Nuclear Research)
Industry, innovation and infrastructure, Affordable and clean energy
Aluminum Alloys Composites Properties
DOIOpen Access PDFOpenAlex
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AluVolt-G™: Scalable Shear-Assisted Solid-State Extrusion of Graphene-Reinforced Aluminum Busbars for 800V Electric Vehicles — Antigravity Advanced Materials Laboratory · Zenodo (CERN European Organization for Nuclear Research) (2026) | TGRS Research Map | TGRS