INDUSTRIAL SEMISOLID CASTING PROCESS FOR SECONDARY ALUMINIUM ALLOYS FOR DECARBONISING LIGHTWEIGHT PARTS IN AUTOMOTIVE SECTOR
The life cycle holistic approach for the automotive sector highlighted how much important is working on decarbonisation of Al casting processes to produce vehicle components. Broadening the use of recycled aluminium alloys, instead of high energy intensive primary aluminium alloys, is key for enviro...
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2020-01-01
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doaj-1093e279ca6c4ff69a915646155971102021-08-05T13:52:23ZengEDP SciencesMATEC Web of Conferences2261-236X2020-01-013260600710.1051/matecconf/202032606007matecconf_icaa172020_06007INDUSTRIAL SEMISOLID CASTING PROCESS FOR SECONDARY ALUMINIUM ALLOYS FOR DECARBONISING LIGHTWEIGHT PARTS IN AUTOMOTIVE SECTORD’Errico Fabrizio0Casari Daniele1Alemani Mattia2Perricone Guido3Tosto Mauro4Politecnico di Milano, Department of Mechanical EngineeringBrembo SpABrembo SpABrembo SpABrembo SpAThe life cycle holistic approach for the automotive sector highlighted how much important is working on decarbonisation of Al casting processes to produce vehicle components. Broadening the use of recycled aluminium alloys, instead of high energy intensive primary aluminium alloys, is key for environment preservation. While primary aluminium alloys are preferred by automotive original equipment manufacturers (OEMs) because impurities (mainly Fe) present in secondary aluminium alloys might cause fatigue properties decay, a new semisolid state process route has been developed at Brembo to drastically reduce the sensitivity of cast aluminium to Fe impurities. Based on these premises, during the CRAL European project in the framework of the LIFE Programme, an industrial prototype machinery - a vertical high pressure die casting machine - has been designed and constructed to inject secondary aluminium in the semisolid state. A number of A357 Fe-enriched brake callipers manufactured via the new process route have been fully investigated by fatigue tests, SEM and OM analyses in order to validate the new eco-sustainable product compared to conventional ones manufactured with primary aluminium by gravity casting.https://www.matec-conferences.org/articles/matecconf/pdf/2020/22/matecconf_icaa172020_06007.pdf |
collection |
DOAJ |
language |
English |
format |
Article |
sources |
DOAJ |
author |
D’Errico Fabrizio Casari Daniele Alemani Mattia Perricone Guido Tosto Mauro |
spellingShingle |
D’Errico Fabrizio Casari Daniele Alemani Mattia Perricone Guido Tosto Mauro INDUSTRIAL SEMISOLID CASTING PROCESS FOR SECONDARY ALUMINIUM ALLOYS FOR DECARBONISING LIGHTWEIGHT PARTS IN AUTOMOTIVE SECTOR MATEC Web of Conferences |
author_facet |
D’Errico Fabrizio Casari Daniele Alemani Mattia Perricone Guido Tosto Mauro |
author_sort |
D’Errico Fabrizio |
title |
INDUSTRIAL SEMISOLID CASTING PROCESS FOR SECONDARY ALUMINIUM ALLOYS FOR DECARBONISING LIGHTWEIGHT PARTS IN AUTOMOTIVE SECTOR |
title_short |
INDUSTRIAL SEMISOLID CASTING PROCESS FOR SECONDARY ALUMINIUM ALLOYS FOR DECARBONISING LIGHTWEIGHT PARTS IN AUTOMOTIVE SECTOR |
title_full |
INDUSTRIAL SEMISOLID CASTING PROCESS FOR SECONDARY ALUMINIUM ALLOYS FOR DECARBONISING LIGHTWEIGHT PARTS IN AUTOMOTIVE SECTOR |
title_fullStr |
INDUSTRIAL SEMISOLID CASTING PROCESS FOR SECONDARY ALUMINIUM ALLOYS FOR DECARBONISING LIGHTWEIGHT PARTS IN AUTOMOTIVE SECTOR |
title_full_unstemmed |
INDUSTRIAL SEMISOLID CASTING PROCESS FOR SECONDARY ALUMINIUM ALLOYS FOR DECARBONISING LIGHTWEIGHT PARTS IN AUTOMOTIVE SECTOR |
title_sort |
industrial semisolid casting process for secondary aluminium alloys for decarbonising lightweight parts in automotive sector |
publisher |
EDP Sciences |
series |
MATEC Web of Conferences |
issn |
2261-236X |
publishDate |
2020-01-01 |
description |
The life cycle holistic approach for the automotive sector highlighted how much important is working on decarbonisation of Al casting processes to produce vehicle components. Broadening the use of recycled aluminium alloys, instead of high energy intensive primary aluminium alloys, is key for environment preservation. While primary aluminium alloys are preferred by automotive original equipment manufacturers (OEMs) because impurities (mainly Fe) present in secondary aluminium alloys might cause fatigue properties decay, a new semisolid state process route has been developed at Brembo to drastically reduce the sensitivity of cast aluminium to Fe impurities. Based on these premises, during the CRAL European project in the framework of the LIFE Programme, an industrial prototype machinery - a vertical high pressure die casting machine - has been designed and constructed to inject secondary aluminium in the semisolid state. A number of A357 Fe-enriched brake callipers manufactured via the new process route have been fully investigated by fatigue tests, SEM and OM analyses in order to validate the new eco-sustainable product compared to conventional ones manufactured with primary aluminium by gravity casting. |
url |
https://www.matec-conferences.org/articles/matecconf/pdf/2020/22/matecconf_icaa172020_06007.pdf |
work_keys_str_mv |
AT derricofabrizio industrialsemisolidcastingprocessforsecondaryaluminiumalloysfordecarbonisinglightweightpartsinautomotivesector AT casaridaniele industrialsemisolidcastingprocessforsecondaryaluminiumalloysfordecarbonisinglightweightpartsinautomotivesector AT alemanimattia industrialsemisolidcastingprocessforsecondaryaluminiumalloysfordecarbonisinglightweightpartsinautomotivesector AT perriconeguido industrialsemisolidcastingprocessforsecondaryaluminiumalloysfordecarbonisinglightweightpartsinautomotivesector AT tostomauro industrialsemisolidcastingprocessforsecondaryaluminiumalloysfordecarbonisinglightweightpartsinautomotivesector |
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