Increased use of recycled aluminium in foundry processes

Important results from the project

The project has successfully met its main objectives. LCA results show lower CO2 emissions than existing databases and a reverse ranking of alloys. Tests showed that even small increases in copper degrade corrosion resistance, making it difficult to raise the acceptance level. The influence of Fe-rich phases on mechanical properties was analysed, but industrial practice did not give the desired results. The project has still created value for industry and laid a foundation for future innovation.

Expected long term effects

LCA shows that the studied alloys have lower CO2 emissions compared to available databases, these therefore need to be updated for correct environmental assessments. Analysis shows that small amounts of copper reduce corrosion resistance, which requires high quality requirements for recycled aluminium. Knowledge of the impact of iron-rich phases on strength provides valuable input for future material development, although modification trials did not give the expected results.

Approach and implementation

The work was carried out with emphasis on 3 areas: alloy for permanent mould casting, alloy for HPDC and LCA. Samples were cast with great variation in lab scale to reduce number of alloy variants that were eventually cast with industrial methods. We had challenges with quality of test rods manufactured in lab, which meant no component casting for the permanent mould alloy. The cooperation between the parties has worked very well and has been crucial to the success of the project