Periodic Reporting for period 3 - FLAMINGo (Fabrication of Lightweight Aluminium Metal matrix composites and validation In Green vehicles)
Berichtszeitraum: 2024-02-01 bis 2025-01-31
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. When Nanoparticles are uniformly distributed within the aluminium matrix, they hinder dislocation movement and reduce their ability to slip. Moreover, Nanoparticles act as nucleation sites during the solidification process, promoting the formation of fine grains in the aluminium matrix. Smaller grain sizes result in increased strength and hardness due to grain boundary strengthening. Thanks to these multiple strengthening mechanisms, an increase in the yield strength has been achieved.
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 current practices? Is it cost-effective?
These are also the challenges that FLAMINGo is tackling, aiming to formulate an Aluminium Metal Matrix nano-Composite 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. When Nanoparticles are uniformly distributed within the aluminium matrix, they hinder dislocation movement and reduce their ability to slip. Moreover, Nanoparticles act as nucleation sites during the solidification process, promoting the formation of fine grains in the aluminium matrix. Smaller grain sizes result in increased strength and hardness due to grain boundary strengthening. Thanks to these multiple strengthening mechanisms, an increase in the yield strength has been achieved.
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 current practices? Is it cost-effective?
These are also the challenges that FLAMINGo is tackling, aiming to formulate an Aluminium Metal Matrix nano-Composite that could be adopted by OEM to replace steel in components for EVs.
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.
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.
FLAMINGo is revolutionising the way we use aluminium alloys by integrating nanoparticles into their production processes. We're not just introducing nanoparticles; we're looking at every step of the process, from start to finish, to make sure we're creating materials that are not only high-performance but also environmentally friendly.
We're evaluating how these nanoparticles affect the properties of the materials, optimising manufacturing processes, and even considering how they can be seamlessly integrated into existing industrial practices. Our goal is to simplify the adoption of these nano-enhanced materials in aluminium industries while ensuring they meet the highest standards of health, safety, and ecological responsibility.
We've already made significant progress in manufacturing master alloys for aluminium metal matrix nano-composites, and we're now moving into pilot-scale trials for casting and extrusion. The results so far have been incredibly promising, showing improvements in mechanical properties and the optimization of component designs.
But we're not stopping there. We're continuing to refine our processes to achieve the perfect balance between cost and performance. This will make these innovative solutions not only effective but also economically viable for widespread adoption in the market.
The solutions developed by FLAMINGo, along with those of other projects in the EnLightEVs Cluster, are set to revolutionise the electric vehicle industry. By reducing the weight of EVs while maintaining structural integrity, safety for passengers and workers, and sustainability through eco-design and circular practices, we're paving the way for a greener, more efficient future.
We're evaluating how these nanoparticles affect the properties of the materials, optimising manufacturing processes, and even considering how they can be seamlessly integrated into existing industrial practices. Our goal is to simplify the adoption of these nano-enhanced materials in aluminium industries while ensuring they meet the highest standards of health, safety, and ecological responsibility.
We've already made significant progress in manufacturing master alloys for aluminium metal matrix nano-composites, and we're now moving into pilot-scale trials for casting and extrusion. The results so far have been incredibly promising, showing improvements in mechanical properties and the optimization of component designs.
But we're not stopping there. We're continuing to refine our processes to achieve the perfect balance between cost and performance. This will make these innovative solutions not only effective but also economically viable for widespread adoption in the market.
The solutions developed by FLAMINGo, along with those of other projects in the EnLightEVs Cluster, are set to revolutionise the electric vehicle industry. By reducing the weight of EVs while maintaining structural integrity, safety for passengers and workers, and sustainability through eco-design and circular practices, we're paving the way for a greener, more efficient future.