Climate-smart high-performance aluminium (ClimAl)

Purpose and goal

The aim is to facilitate the broader use of aluminium sheets based on recycled material to reduce the carbon footprint. Using recycled material also increases the possibilities for raw material procurement. The project´s primary goal is to improve resource efficiency through process innovation that affects objectives 5A and 5D. The use of recycled material also affects stage 6 with significantly reduced environmental impact through a reduced need for material downgrading and better use of scrap with an indirect effect on 6G.

Expected results and effects

Polestar´s strive towards carbon-free manufacturing is challenging for components made from alumnium sheets. This is due to the fact that use of recycled metal leads to poorer formability. The project´s expected results are alloy principles for an acceptable castability and rollability for sheet metal manufacturing, combined with an innovative process route for sheet metal forming. This should result in a robust process path which, independent of trace elements (within reasonable limits), offers a good combination of formability and component properties.

Planned approach and implementation

The project is run in 6 different work packages to 1. Analyze and identify critical trace elements that affect recrystallization and strain hardening, focusing on so-called "cocktail effects". 2. Develop and test alloying principles to increase the use of secondary aluminium sources for a rolled product for appropriate demonstrators to meet the requirements. 3. Broaden the number of available aluminium alloys whose specifications readily accept recycled metal and work well in high-quality, refined products with a minimum climate impact.