Optimizing process windows and quality assurance for robust mechanical joints in recycled cast alumnium parts

Purpose and goal

OptiCAP addresses key challenges in joinability, quality assurance and repair methods for cast aluminum components. Aluminum castings, especially recycled materials, present joining challenges due to low and variable ductility and material defects. OptiCAP´s objective is to enable robust, scalable and qualified mechanical joining of cast aluminum components with a high recycling rate in large-scale production.

Expected effects and result

A key effort is the development of validated joinability criteria and automated methods for quality control. This provides industry with objective tools for design and process decisions, improves joint performance and reduces the need for prototype materials. The project also develops robust process windows using in-line QA data. Furthermore, strategies for reuse, repair and material separation are developed – key enablers for a circular economy.

Planned approach and implementation

The project is divided into five work packages (WPs) that together address material properties, optimized joinability analysis and process windows, optimized quality assurance, optimized circularity and project management. WP1: Material testing and test geometries WP2: Methods for quality control of materials and joints WP3: Development and optimization of process windows WP4: Joining of recycled materials, recycling practices, disassembly and repair methods WP5: Project management