Periodic Reporting for period 1 - FLAMINGo (Fabrication of Lightweight Aluminium Metal matrix composites and validation In Green vehicles)
Período documentado: 2021-02-01 hasta 2022-07-31
The synthesis of lightweight materials with high strength has long been a challenge for engineers and material scientists. The combination of these two properties makes these materials highly desirable in the aerospace and automotive industries. Particularly as the electrical revolution for more Battery Electric Vehicles continues to grow, trying to tackle the climate change problem, the Original Equipment Manufacturers (OEMs) are looking to adopt the use of new materials in their designs, with the knowledge that a 10% reduction in vehicle weight can improve fuel economy by 6-8%.
The addition of ceramic Nano-particles as a reinforcement to aluminium alloys has proven to be an effective method for enhancing the material properties. Many studies have shown that aluminium metal matrix nano-composites (Al-MMnC) have superior mechanical properties when compared to their base alloys. Thanks to multiple strengthening mechanisms caused by the presence of nanoparticles an increase of the yield strength by up to 60% can be achieved in some aluminum alloys.
But there are many open questions that need to be addressed before seeing Al-MMnC substituting steel components in Battery Electric Vehicles: How to handle nanoparticles? How effectively disperse them in industrial casting processes? Can Al-MMnC be extruded? Are the resulting components weldable? Is it also recyclable considering currently practices? Is it cost effective?
These are also the challenges that FLAMINGo is tackling, aiming to formulate an Aluminium Metal Matrix nanoComposite that could be adopted by OEM to replace steel in components for EVs.
The addition of ceramic Nano-particles as a reinforcement to aluminium alloys has proven to be an effective method for enhancing the material properties. Many studies have shown that aluminium metal matrix nano-composites (Al-MMnC) have superior mechanical properties when compared to their base alloys. Thanks to multiple strengthening mechanisms caused by the presence of nanoparticles an increase of the yield strength by up to 60% can be achieved in some aluminum alloys.
But there are many open questions that need to be addressed before seeing Al-MMnC substituting steel components in Battery Electric Vehicles: How to handle nanoparticles? How effectively disperse them in industrial casting processes? Can Al-MMnC be extruded? Are the resulting components weldable? Is it also recyclable considering currently practices? Is it cost effective?
These are also the challenges that FLAMINGo is tackling, aiming to formulate an Aluminium Metal Matrix nanoComposite that could be adopted by OEM to replace steel in components for EVs.
The partners in FLAMINGo have defined two reference EV parts that will be representative of wide classes of EV components, and in particular of the reference ATX utility vehicle. These are the steering knuckle, which will be obtained by casting, and the rear frame, which will be obtained by extrusion and welding. The design optimisation alone and the FEM analysis confirmed that the expected weight reduction ranges from 30% to 50% on the selected components.
The synthesis of nano-additives for the production of Al-MMnC in the casting and extrusion industries has been scaled to pre-industrial level, for a production scale of hundreds of kg of Al-MMnC per day, suitable for extensive testing by multiple techniques at industrially relevant scale.
Promising results have been reached with more than one nanoparticle variant, obtaining up to +30% in YS, compared to the base alloy without NP. The most effective combination of cost/performance is still under development, considering that FLAMINGo has a cost target of 3€ for kg saved.
The Technical Developmentsare supported by transversal activities that will assure FLALMINGo solution to be consistent with European HSE requirements: a study on nanosafety for workers is ongoing, to assess if any possible release of nanoparticles can be detected in the different processing steps, the evaluation of the environmental impact of the new component and their effect of the life cycle of the entire vehicle has been started as well as the analysis of Al-MMnC in the recycling processes.
11 Key Exploitable Results have been identified within the consortium, starting the elaboration of a sound and effective exploitation plan for the evolving technologies and products related to Al-MMnC, highlighting their competitive advantages. Many dissemination activities were also performed, including the set-up of a project website (www.flamingo-project.eu) the editing of printed materials, many social media posts and updates, the attendance to topic-specific events, the intensive clustering activities with other projects dealing with the improvements of EVs’ efficiency.
The synthesis of nano-additives for the production of Al-MMnC in the casting and extrusion industries has been scaled to pre-industrial level, for a production scale of hundreds of kg of Al-MMnC per day, suitable for extensive testing by multiple techniques at industrially relevant scale.
Promising results have been reached with more than one nanoparticle variant, obtaining up to +30% in YS, compared to the base alloy without NP. The most effective combination of cost/performance is still under development, considering that FLAMINGo has a cost target of 3€ for kg saved.
The Technical Developmentsare supported by transversal activities that will assure FLALMINGo solution to be consistent with European HSE requirements: a study on nanosafety for workers is ongoing, to assess if any possible release of nanoparticles can be detected in the different processing steps, the evaluation of the environmental impact of the new component and their effect of the life cycle of the entire vehicle has been started as well as the analysis of Al-MMnC in the recycling processes.
11 Key Exploitable Results have been identified within the consortium, starting the elaboration of a sound and effective exploitation plan for the evolving technologies and products related to Al-MMnC, highlighting their competitive advantages. Many dissemination activities were also performed, including the set-up of a project website (www.flamingo-project.eu) the editing of printed materials, many social media posts and updates, the attendance to topic-specific events, the intensive clustering activities with other projects dealing with the improvements of EVs’ efficiency.
FLAMINGo will provide material solutions ready for the market, simplifying the integration of nano-enabled composites at processing lines for Aluminium industries and evaluating all the Health Safety and Ecological aspect that might hinder their uptake.
The manufacturing of Master-alloys for the production of the Aluminium Metal Matrix Nano-composites has already reached the pre-industrial scale whereas casting and extrusion trials are beginning at pilot scale.
The positive results reached so far on the mechanical properties and on the components’ topology optimization are being further developed to reach a balanced cost/performance ratio that will enable an effective introduction of these solution into the market.
FLAMINGo solutions, along with those of the other projects in the EnLightEVs Cluster,will be rapidly applicable by industries to reduce EVs weight, while considering structural integrity, passengers’ and workers' safety, and sustainability, through eco-design and circular practices.
The manufacturing of Master-alloys for the production of the Aluminium Metal Matrix Nano-composites has already reached the pre-industrial scale whereas casting and extrusion trials are beginning at pilot scale.
The positive results reached so far on the mechanical properties and on the components’ topology optimization are being further developed to reach a balanced cost/performance ratio that will enable an effective introduction of these solution into the market.
FLAMINGo solutions, along with those of the other projects in the EnLightEVs Cluster,will be rapidly applicable by industries to reduce EVs weight, while considering structural integrity, passengers’ and workers' safety, and sustainability, through eco-design and circular practices.