Improved alloys for demanding applications

In transport and energy, minimising weight reduces the work needed to move the products and thus reduces energy consumption and emissions. In the construction sector, it facilitates more complex and taller structures that are easier to put in place. Lightweight alloys of aluminium (Al) or magnesium (Mg) are gaining interest, but there is a need to improve their mechanical properties.

One promising solution combines them with some type of reinforcement. The EU is funding the project EFEVE (Development of a new high performance material associated to a new technological energetic, flexible, economical, versatile and ecological process to make super strong and lightweight components) to develop new nano-reinforced alloys and associated eco-friendly casting processes. The materials and processes will reduce weight by 30 %, energy usage by 20 % and manufacturing costs by 10 % while delivering a better product, thus providing a sustainable competitive boost. Technologies will be showcased with four demonstrators.

The nano-reinforcements play a critical role in the microstructure and mechanical properties of the finished product. To date, the team has developed cost-effective nano-reinforcements and is minimising agglomeration for improved dispersion and distribution. The focus is on industrially scalable processes and safe handling procedures.

Mg alloys will be produced by squeeze casting and Al alloys by hybrid low-pressure squeeze casting (LPSC). Both processes have been evaluated at laboratory scale. The team is moving forward on the groundwork for implementation in industrial pilot lines.

Specifically, the Al LPSC equipment has now been designed. Analysis has identified required changes to an existing high-pressure die casting line to enable Mg squeeze casting. The team has now planned the associated construction, assembly and start-up.

Finally, as energy efficiency and reduction of materials usage are important objectives, researchers have evaluated potential tools and methodologies for their planned life-cycle assessments and energy optimisation. The project website is up and running, presenting all information about the research, including a continuous stream of news and events.

The automotive, wind power and construction sectors demand very strong and lightweight components. EFEVE is improving the mechanical properties of nano-reinforced Al and Mg alloys while decreasing the costs and energy consumption associated with their production for a major boost to the competitiveness of manufacturers and end users.