FLAMINGo Fabrication of Lightweight Aluminium Metal matrix composites and validation In Green vehicles

Summary

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

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Contribution of R&I projects to standardisation

Comment:

An analysis of the standardisation landscape and recommendations were developed to ensure processing of materials with the inclusion of nanoparticles, having in account the important aspect of health and safety with nanoparticles.

More information & hyperlinks

Web resources:	https://cordis.europa.eu/project/id/101007011 https://www.flamingo-project.eu/
Start date:	01-02-2021
End date:	31-01-2025
Total budget - Public funding:	5 276 597,00 Euro - 4 445 411,00 Euro

Cordis data

Original description

"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"