MATEC Web Conf.
Volume 326, 2020The 17th International Conference on Aluminium Alloys 2020 (ICAA17)
|Number of page(s)||6|
|Section||Casting & Solidification, Recycling, Fundamentals of Additive Manufacturing|
|Published online||05 November 2020|
INDUSTRIAL SEMISOLID CASTING PROCESS FOR SECONDARY ALUMINIUM ALLOYS FOR DECARBONISING LIGHTWEIGHT PARTS IN AUTOMOTIVE SECTOR
1 Politecnico di Milano, Department of Mechanical Engineering, 20156 Milan, Italy
2 Brembo SpA, 24040, Stezzano, Italy
* Corresponding author: firstname.lastname@example.org
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.
© The Authors, published by EDP Sciences, 2020
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