FLAMINGo aimed to develop and validate advanced lightweight aluminum metal matrix composites (Al-MMnCs) for electric vehicle (EV) applications. Two reference components were selected: a steering knuckle produced via casting and a rear frame made through extrusion and welding. These components were designed and optimized to demonstrate substantial weight reductions at a component level —up to 47% compared to steel counterparts—without compromising mechanical performance. The optimized designs were successfully integrated and tested in a full-scale demonstrator vehicle (ATX-4), confirming their functionality and alignment with target requirements.
The project scaled the production of Al-MMnC materials to pre-industrial levels, achieving daily outputs of hundreds of kilograms to enable trials under industrial conditions. Master alloys enriched with SiC and TiC nanoparticles were developed and assessed, with the most promising formulations delivering up to 30% improvement in mechanical properties in some Matrix/NP/Process combinations. Although nanoparticle effects diminished in some cases due to post-processing heat treatments, significant performance gains and manufacturing consistency were achieved. Extrusion, welding, and casting processes were validated, including fatigue testing and non-destructive inspections, confirming structural integrity and reliable processability.
Environmental sustainability and safety were key pillars of FLAMINGo. A full Life Cycle Assessment (LCA) and Life Cycle Cost Assessment (LCCA) were completed, evaluating the impact of substituting steel with Al-MMnC at both component and vehicle levels. Recycling trials showed that both SiC- and TiC-based Al-MMnCs can be reintegrated into conventional aluminum recycling streams with over 91% recovery rates. The use of fluxes and degassing steps reduced nanoparticle concentration, while preserving base alloy quality. Nanosafety assessments across synthesis, processing, and recycling confirmed low risk of nanoparticle release, leading to the development of specific H&S guidelines for safe handling.
Overall, FLAMINGo demonstrated the feasibility of using Al-MMnC materials for high-performance, lightweight, and sustainable EV components. The technical achievements, combined with robust validation and exploitation strategies, provide a solid foundation for further industrial development and commercialization.
