Project description
An innovative improved manufacturing approach with direct application to electric automotive engineering
Aluminium composite materials are an industrial solution with multiple applications. As a result, the industrial manufacturing sector is in constant search for ways to improve their production. Among others, the battery-electric vehicle (BEV) technology is a significant factor for the intensification of their use. To address these challenges, the EU-funded FLAMINGo project will propose a novel metallurgical and forming combined approach for making automotive parts. FLAMINGo will focus on manufacturing strengthened aluminium (Al) metal matrix composites with elevated properties compared to current Al alloys used in automotive. By substituting steel components in BEV automotive parts, the project also aims to achieve a substantial weight reduction.
Objective
"FLAMINGo will propose a novel industrial manufacturing route for the efficient production of high performance lightweight Aluminum composite materials thanks to a novel metallurgical and forming combined approach for making automotive parts. The intensification of use of the Aluminium composites will be driven mainly by the battery-electric vehicle (BEV) technology that are forcing automakers to look for innovative ways to lightweight the vehicles. The goals of FLAMINGo will be related to the manufacturing of a strengthened Aluminium Metal Matrix Composites Al-MMC with elevated properties (+200% strength and +30% stiffness) compared to current Al alloys used in automotive. FLAMINGo will provide engineering solutions to substitute steel components in BEV automotive parts and achieve a substantial reduction of weight (up to 20%). To reach these goals the project will target the following development steps at prototype and full scale: # The production of nanoparticles concentrated masterbatches of Al-MMC, via solid state mechanical alloying, to assure a complete dispersion of the nanoparticles in the Al metal before inoculation in the melt # Casting of Al-MMC components by inoculating the masterbatch in an Al melt, and homogenized by ultrasonication and electromagnetic stirring systems # Production of smaller components (brackets and connectors) by Low Pressure Die Casting LPDC and bigger components, like subframes, by Green Sand Casting to demonstrate broader feasibility and applicability of Al-MMC. # Extrusion of cast billets for making profiles for the body frame # Identification of the welding techniques for joining Al-MMC components, and assessment of the application via TIG, GTAW and RSW. # Use of these components for substitution of steels and aluminium parts in electric vehicles, validation of components estimated service life and installation on vehicles. # Recycling of Al-MMC components supported also by the use of secondary aluminium in the formulation"
Fields of science
- engineering and technologyenvironmental engineeringwaste managementwaste treatment processesrecycling
- social sciencessocial geographytransportelectric vehicles
- engineering and technologymaterials engineeringcomposites
- natural scienceschemical sciencesinorganic chemistrypost-transition metals
- engineering and technologynanotechnologynano-materials
Programme(s)
Topic(s)
Funding Scheme
IA - Innovation actionCoordinator
31030 Carbonera
Italy
The organization defined itself as SME (small and medium-sized enterprise) at the time the Grant Agreement was signed.