Fabricating metal composite components for electric vehicles

Fabrication of lightweight aluminium metal matrix composites and validation in green vehicles - FLAMINGo.

This project aims to develop a group of integrated technologies that will enable the uptake and use of Aluminium Metal Matrix Composites (Al-MMCs) in electric vehicles. This will involve advancements in technologies such as mechanochemical alloying and mixing, manufacturing methods such as Green Sand Casting, Low-Pressure Die Casting, Extrusion and Welding, as well as in topology optimization and recycling processes. In order to boost EV market adoption, it is important that innovative technological solutions are provided that will lift existing technical barriers and will lead to both improved efficiency and increase range. To reach these goals the project will target the following development steps at the prototype and full scale:

• The production of nanoparticles concentrated masterbatches of Al-MMC, in order to insure a complete dispersion of the nanoparticles in the Al.
• Casting of Al-MMC components by inoculating the Al melt, and homogenising the distribution.
• Production of smaller components (e.g. brackets and connectors) by Low Pressure Die Casting and larger components, like subframes, by Green Sand Casting to demonstrate the broader feasibility and applicability of Al-MMCs.
• Extrusion of cast billets for making profiles for the body frame.
• Identification of the welding techniques (e.g. TIG, GTAW and RSW) suitable for joining Al-MMC components, and assessment of the application.
• Use of these components for substitution of steels and aluminium parts in electric vehicles, validation of components estimated service life and installation on vehicles.
• Practices to recycle the Al-MMC components.