Advanced Manufacturing, Reliability Assessment, and Sealing Design of Critical NEV Components Under Complex Operational Extremes

Abstract

The accelerating transition toward sustainable e-mobility demands unprecedented performance from core components of new energy vehicles, assemblies that routinely encounter highly complex and extreme operational environments. This study addresses the deeply interwoven challenges of precision manufacturing, reliability evaluation, and sealing structure design for these critical powertrain systems. By navigating unexpected material non-linearities during high-precision machining and actively reconciling systemic discrepancies between accelerated laboratory testing and the actual multi-physics field degradation observed in real-world scenarios, we developed an adaptive manufacturing-evaluation-sealing framework. Experimental observations regarding interfacial stress relaxation suggest that conventional static models may, to some extent, misestimate long-term sealing efficacy under transient thermal-mechanical coupling, pointing to a critical need to consider secondary visco-elastic behaviors. While our integrated optimization paradigm yields notable improvements in component robustness, subtle variations in micro-structural integrity across processing batches imply that further research is required to fully decouple manufacturing-induced residual stresses from operational fatigue mechanisms. Considering the above factors, this research provides nuanced insights that bridge the gap between idealized structural configurations and practical manufacturing uncertainties, potentially offering a more resilient path for next-generation powertrain development.