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Overview of the FLAMINGo Project

FLAMINGo will propose a novel industrial manufacturing route for the efficient production of high-performance lightweight Aluminium composite materials thanks to a novel metallurgical and forming combined approach for making automotive parts. The intensification of use of the Aluminum 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 Aluminum Metal Matrix nano-Composites Al-MMnC with elevated properties, in terms of strength and 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.To be effective in introducing the new materials in the market the project will target the following development steps: 

  • The production of Al-MMnC via solid state mechanical alloying.
  • The casting of Al-MMnC components by inoculating the masterbatch in an Al melt, and homogenized by ultrasonication and electromagnetic stirring systems.
  •  The 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-MMnC. 
  • The extrusion of cast billets for making profiles for the body frame.
  • The weldability assessment of Al-MMnCs using a range of welding technologies (MIG, resistance spot and arc stud welding processes)
  • The topology optimisation/process simulation enabling the reduction of material per part without losing
    performances
  • The usage of these components for substitution of steel and aluminium parts in electric vehicles, validation of components estimated service life, and installation on vehicles. 
  • Validation of recycling of Al-MMnC components supported also by the use of secondary aluminium in the formulation. 
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