FLAMINGO

Lightweight Aluminium Metal matrix nano-composites and validation In Green vehicles

Alke' is industrial partner of FLAMINGO project which brings together a European Network of 11 highly specialized partners from different fields. The main purposes of this project are:

The manufacturing of a strengthened Aluminum Metal Matrix nano-Composites Al-MMnC with elevated properties.
To provide engineering solutions to substitute steel components in BEV automotive parts and achieve a substantial reduction of weight.

The electric vehicles industry is following the continuously increasing market rates due to the environmental concerns, that lead to regulatory actions and initiatives by governments. Moreover, aluminium is used extensively in the automotive industry because of its lightweight properties. The FLAMINGo project aims to develop lightweight aluminium nanocomposites for the Green Vehicles industry, establishing it as a market trend-oriented project. The FLAMINGo Project aims to manufacture strengthened Aluminium Metal Matrix nano-Composites, Al-MMnC, with enhanced properties in terms of strength and stiffness, compared to the existed Al alloys used in Green Vehicles.
The impact will consist of: Vehicle weight reduction and improvement of existing aluminium properties. Short lead time, by deep integration of combined material modeling into the value chain of product development and manufacturing. Monitoring and control to ensure structural integrity and safety of the FLAMINGo components and their adoption in Utility Vehicles, Electric Vehicles, Aerospace. Compliance with circularity and zero-emission legislation.
ALKE is the leader for WP2 and WP7, related to the design and topology optimization, as well as the validation and demonstration of components.

The FLAMINGO objectives

To produce Al-MMnC materials (utilizing primary and secondary Al sources) via solid-state mechanical alloying, capable to assure a complete dispersion of the nanoparticles.
To re-design automotive components and parts by applying topology optimisation methods for reduction of their weight, maintaining, their structural integrity and properties.
To optimise Green Sand Casting and Low Pressure Die casting methods for the production of Al-MMnC components based automotive parts with enhanced nanoparticles distribution in the matrix, utilising also simulation and modeling tools.
To optimise the extrusion process of Al-MMnC components, achieving replacement of steel systems utilizing alloys formulated from recycled and end-of-life scrap.
To optimise welding techniques and join Al-MMnC automotive parts avoiding segregation of reinforcement particles in the bonding region.
To prove the recyclability of the Al-MMnC component by safe removal of the reinforcing nanoparticles during the re-melting process.
To manufacture BIW, automotive components, using the Al-MMnCs in casting and extrusion pilot lines.
To integrate the produced parts and components in real scale electric vehicle and proceed with quality control tests.

For more details on FLAMINGO project see: www.flamingo-project.eu.
This Project has received funding from the European Community’s H2020 Programme under the grant agreement Nr. 101007011 Funding Scheme: H2020-LC-GV-2020.
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