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Tesla patents aluminum “spray quench” process for molecular-level strengthening

The Tesla Model Y body shop in Fremont, CA. (Credit: Tesla)

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Tesla has submitted a patent that describes a new, more effective cooling process for manufacturing high-strength aluminum components to be used in its product line.

The patent entitled, “System and Method for Facilitating Pulsed Spray Quench of Extruded Objects”, describes a quenching process that aims to increase the strength, rigidity, and energy absorption of aluminum alloy components. A multi-way spray nozzle system would cool extruded aluminum with an atomized spray of liquid.

“A system includes a billet die at a proximal end configured to accept a billet and form an extrudate, a quench chamber located adjacent to the billet die for receiving the extrudate and comprising at least one pulsed width modulation (PWM) atomizing spray nozzle and a control module in communication with the at least one PWM atomizing spray nozzle and configured to independently control a liquid pressure, a gas pressure, a spray frequency, a duty cycle and flow rate of each at least one PWM atomizing spray nozzle,” reads the patent abstract.

Vehicles today use 6XXX aluminum alloys, which make up the front and rear bumpers, side and back steps, and knee bolsters of a car, the Kobelco Technology Review stated. Tesla also indicates within the patent that it uses 6XXX alloys for its vehicles. After these parts are extruded, they enter a quenching process, which is simply the process of cooling the metal after it has been heated.

Currently, Tesla utilizes a quenching process that involves cooling recently extruded aluminum alloys by soaking the parts in water. This process of quenching is recognized as “quick cooling.” While other cooling means are available, such as air cooling and furnace cooling, soaking the parts in water is the most time-effective method for automotive manufacturing.

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The aluminum extrusion process that Tesla currently uses is soaking the metal in water. This is called “Quick-Cooling.” (Credit: YouTube | ILSCO Extrustions Inc)

However, Tesla’s patent recognizes the adverse effects that quick cooling aluminum alloy parts can have on the structural integrity of the metal. Quick-cooling can not only lead to deformation and warping of metal parts, but things can change chemically as well.

Magnesium silicide, or Mg2Si, is present in these aluminum alloy parts, and quick cooling them can inhibit the compound’s ability to set in the metal. Without the proper setting of Mg2Si by quick-cooling the aluminum alloy in water, the metal requires a higher extrusion pressure and becomes more sensitive to heat, according to Light Metals 2014. The combination of these two properties can effectively compromise the mechanical properties of the final product, making the frame of the vehicle lose strength through the manufacturing process.

Tesla plans to utilize a multi-way spraying system to cool extruded aluminum parts, eliminating the soaking process that is used by so many manufacturers of aluminum alloy. In the patent, the company describes a quenching system that would spray newly extruded metals at varying rates depending on the size of the part. Between one half-gallon and 10 gallons of water per minute would cool the metal in question.

Two pyrometers would be placed at both the proximal and distal ends of the quench chamber. These would hold the responsibility of maintaining the metal’s temperature through the quenching process. The pyrometers would communicate with the system to ensure proper cooling temperatures, making sure the aluminum does not cool too quickly, allowing the Mg2Si to set. In conjunction with the temperature control, spray frequency, liquid pressure, gas pressure, and flow rate will also be monitored to ensure maximum strength after extradition is complete.

Tesla’s recognition of the flaws in quick-cooling extruded metals indicates the company’s realization that increased strength of a car’s frame could improve with a more efficient cooling technique.

In the teardown of the Model Y, Sandy Munro complimented Tesla’s use of what he called the “aluminum rear crush plate.” The piece is located at the trunk hatch and is designed to fold in the event of a rear-impact. The part saves the sides of the body from being compromised in a crash, which can ultimately total the vehicle if the chassis bends excessively.

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Tesla Model Y’s Aluminum Rear Crush Plate. (Credit: YouTube | MunroLive)

While the crush plate is durable and prevents excessive damage to the body of the Model Y, the quick-cooling process used during manufacturing could ultimately make the crush plate less sustainable than what it could be. Not to mention, the front bumper, rear bumper, side and back steps, and knee bolsters are also made of aluminum. Using a different cooling technique could eventually lead to an even safer Tesla vehicle, which already has many five-star crash safety ratings from several organizations located around the world.

Read Tesla’s patent for a new aluminum cooling process below.

Tesla SYSTEM AND METHOD FOR FACILITATING PULSED SPRAY QUENCH OF EXTRUDED OBJECTS by Joey Klender on Scribd

Joey has been a journalist covering electric mobility at TESLARATI since August 2019. In his spare time, Joey is playing golf, watching MMA, or cheering on any of his favorite sports teams, including the Baltimore Ravens and Orioles, Miami Heat, Washington Capitals, and Penn State Nittany Lions. You can get in touch with joey at joey@teslarati.com. He is also on X @KlenderJoey. If you're looking for great Tesla accessories, check out shop.teslarati.com

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Canaccord reaffirms Tesla’s price target of $404 after Giga Texas visit

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Credit: Tesla Asia/X

Canaccord Genuity reaffirmed its price target of $404 for Tesla after a visit to Gigafactory Texas. The investment firm sees an optimistic future for Tesla in the long term despite near-term headwinds.

Canaccord analysts reiterated its “Buy” rating for TSLA stock and revised Tesla’s Q1 2025 delivery estimates from ~331,000 vehicles to ~362,000 units. The firm’s first-quarter delivery estimates for Tesla reveal its optimistic take on the company’s future, even though it is still below the consensus estimate of ~417,000 vehicles.

“Our estimate is informed by our opinion that some consumers are delaying vehicle purchases to access the new Model Y and 4Q24 earnings call commentary regarding Model Y-related factory retooling limiting production…We wonder whether purchase decision delays and production limitations are being misinterpreted as halted overall momentum for Tesla. While we do suspect there has been some macroeconomic/brand impact, we, again, do estimate 1Q25 deliveries are mostly being impacted by supply constraints–as well as some demand factors,” Canaccord Genuity noted.

Canaccord analysts recently visited Tesla Giga Texas and left with optimism for the American electric vehicle (EV) maker.

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“It’s hard not to be impressed with how future-forward Tesla is–whether it’s vehicle design or manufacturing. Consistently rethinking the status quo,” Canaccord Genuity analysts commented.

Analysts highlighted Tesla’s progress with Full Self-Driving, specifically version 13.2.8. They noted that Tesla’s unboxed manufacturing strategy would boost production efficiencies. Canaccord Genuity analysts also mentioned that Tesla’s robotaxi services will launch in Austin in the summer.

“For investors with duration and grit, there is a silver-linings playbook,” the Canaccord Genuity analysts concluded.

Canaccord Genuity reflects Elon Musk’s recent stock market advice during the Tesla All-Hands keynote. Musk advised investors to invest in companies with products they love, highlighting that Tesla has a few great products and will continue to launch more.

“Tesla stock goes up and goes down, but actually, it’s still the same company,” Musk noted.

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Tesla stock rebounds and Tim Walz backtracks: ‘I was making a joke’

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Credit: @TeslaFrenzy/X

Tesla stock rebounded over 20 percent in the past five trading days, and, coincidentally, the boost came just after Tim Walz said he gets a boost from watching the automaker’s shares fall.

Although Walz’s pushback against Tesla stock mostly comes from his evident distaste for CEO Elon Musk, who has joined President Donald Trump’s team as the head of the Department of Government Efficiency (DOGE), it seems he might not have realized the EV maker’s shares make up a portion of his state’s pension fund.

This was something Shark Tank’s Kevin O’Leary mentioned last week after Walz’s comments. However, now that Tesla shares are rising once again, Walz is backtracking by saying that his comment from last week was his attempt at humor.

Walz said:

“I have to be careful about being a smartass. I was making a joke. These people have no sense of humor.”

Tesla shares have rebounded nicely since a substantial drop so far this year.

Although the stock is still down about 28 percent this year, things are looking better for the company as it now shifts its focus to the release of several affordable models, the ramp of the new Model Y “Juniper,” the release of the Cybercab and Robotaxi platform in Texas and California, and other potential catalysts like the Optimus robot.

Tesla aiming to produce first “legion” of Optimus robots this 2025

Last week’s All-Hands meeting from Tesla was publicly broadcast on X and seemed to be the response many investors were hoping for as questions started to seep in regarding Musk’s commitment to the company.

While his attention seems to be on solving government spending and eliminating corruption, it is evident Musk is still paying attention to what is going on at Tesla.

Shares are up over 10 percent at 1:05 p.m. on the East Coast, trading at around $274.

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Shark Tank’s O’Leary roasts Tim Walz over Tesla stock hate session

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Shark Tank personality and legendary investor Kevin O’Leary roasted former Vice Presidential nominee Tim Walz over his comments regarding Tesla shares earlier this week.

Walz, a Minnesota Democrat, said that he recently added Tesla (NASDAQ: TSLA) to his Apple Stocks app so he could watch shares fall as they have encountered plenty of resistance in 2025 so far. He said that anytime he needs a boost, he looks at Tesla shares, which are down 36 percent so far this year:

Walz, among many others, has been critical of Tesla and Elon Musk, especially as the CEO has helped eliminate excess government spending through the Department of Government Efficiency (DOGE).

However, Kevin O’Leary, a legendary investor, showed up on CNN after Walz’s comments to give him a bit of a reality check. O’Leary essentially called Walz out of touch for what he said about Tesla shares, especially considering Tesla made up a good portion of the Minnesota Retirement Fund.

As of June 2024, the pension fund held 1.6 million shares of Tesla stock worth over $319.6 million:

O’Leary continued to slam Walz for his comments:

“That poor guy didn’t check his portfolio and his own pension plan for the state. It’s beyond stupid what he did. What’s the matter with that guy? He doesn’t check the well-being of his own constituents.”

He even called Walz “a bozo” for what he said.

Of course, Walz’s comments are expected considering Musk’s support for the Trump Administration, as the Tesla CEO was a major contributor to the 45th President’s campaign for his second term.

However, it seems extremely out of touch that Walz made these comments without realizing the drop was potentially hurting his fund. While we don’t know if the fund has sold its entire Tesla holdings since June, as a newer, more recent report has not been released yet, it seems unlikely the automaker’s shares are not still making up some portion of the fund.

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