A NOVEL ALUMINIUM ALLOYS DESIGN STRATEGY FOR LOW USAGE OF CRITICAL RAW MATERIALS AND HIGH CASTING PROCESSIBILITY FOR AUTOMOTIVE APPLICATIONS

This introductory paper is the research content of the paper "A NOVEL ALUMINIUM ALLOYS DESIGN STRATEGY FOR LOW USAGE OF CRITICAL RAW MATERIALS AND HIGH CASTING PROCESSIBILITY FOR AUTOMOTIVE APPLICATIONS" published by International Journal of Metalcasting.

Figure 2. Classification of aluminium forming processes used in Audi Q8 BIW structure; adapted from Ref 30.
Figure 2. Classification of aluminium forming processes used in Audi Q8 BIW structure; adapted from Ref 30.

1. Overview:

  • Title: A NOVEL ALUMINIUM ALLOYS DESIGN STRATEGY FOR LOW USAGE OF CRITICAL RAW MATERIALS AND HIGH CASTING PROCESSIBILITY FOR AUTOMOTIVE APPLICATIONS
  • Author: Osama Asghar, Mattia Franceschi, Paolo Ferro and Franco Bonollo
  • Publication Year: 2025
  • Published Journal/Society: International Journal of Metalcasting
  • Keywords: aluminium alloys, critical raw materials, high pressure die casting, alloy design

2. Abstract

The fifth critical raw materials (CRMs) list published by the European Commission (EC) in 2023 poses new restrictions to the usage of lightweight materials in the transportation industry. As per the publication, aluminium (one of the most widely used lightweight metals in the aerospace and automotive industry) has been declared as CRM and an increased criticality trend in its major alloying elements e.g. silicon and magnesium has been observed. Therefore, a novel approach is required to implement the criticality concept in developing new aluminium alloys and their processing for different components in the automotive industry. The present study aims to describe the strategy required to reduce the usage of CRMs in aluminium alloys along with enhanced high-pressure die casting (HPDC) processibility. By integrating criticality and castability assessment, a contribution to the development of sustainable and high-strength aluminium alloys to meet the demands of modern manufacturing while addressing the global resource challenges is presented. This study will also support the implementation of the CRMs concept in materials research and development.

3. Research Background:

Background of the research topic:

Sustainability is a major driver for industrial innovation. The automotive industry is focused on optimizing energy efficiency and reducing CO2 emissions. Material selection and design are key to achieving environmental sustainability.

Status of previous research:

Lightweight metals, particularly aluminium alloys, are crucial for reducing vehicle weight and improving fuel efficiency. However, the European Commission has identified aluminium and its key alloying elements (Si, Mg) as Critical Raw Materials (CRMs) due to supply risks and economic importance. Previous research has focused on lightweighting, but not explicitly on minimizing CRM usage in alloy design.

Need for research:

A new approach is needed to design aluminium alloys that minimize the use of CRMs while maintaining or improving the processability, especially for High-Pressure Die Casting (HPDC), a key manufacturing process in the automotive industry.

4. Research purpose and research question:

Research purpose:

To propose a methodology to reduce CRMs in lightweight material selection, specifically aluminium alloys, while ensuring high HPDC processability.

Core research:

Develop a strategy that integrates criticality assessment (minimizing CRM content) and castability assessment (optimizing HPDC processability) for designing new aluminium alloys.

5. Research methodology

The research methodology combines the material selection methodology of Ashby et al.44 with computational tools, primarily the CALPHAD (CALculation of PHAse Diagram) approach. The design process involves:

  1. Material Library Creation: Selecting a starting aluminium alloy and creating a library of alloys by substituting CRMs (Si, Mg) with non-CRM elements.
  2. Mechanical Performance Estimation: Assessing the mechanical properties achievable with the modified compositions.
  3. Castability Evaluation: Evaluating key castability characteristics (fluidity, solidification shrinkage, slag/dross formation, die soldering, hot tearing) using CALPHAD and newly developed models.
  4. Criticality Assessment: Calculating a criticality index for each alloy composition based on the work of Ferro et al.22,59,60.
  5. Optimization: Selecting alloy systems that offer the best compromise between processing properties, mechanical performance, and low criticality.
  6. Experimental Validation: Future experimental campaigns to verify the optimal solutions.

6. Key research results:

Key research results and presented data analysis:

The paper presents a framework for alloy design, not specific alloy compositions or experimental data. Key results include:

  • A detailed explanation of the criticality concept and its relevance to aluminium alloys.
  • Identification of key castability characteristics for HPDC: fluidity, solidification shrinkage, slag/dross formation, die soldering, and hot tearing.
  • Description of methods to evaluate these characteristics using CALPHAD and other models.
  • Presentation of equations for calculating a criticality index (CICRM) for individual raw materials and an overall alloy criticality index (CIA).
  • Proposal of a multi-objective strategy to combine criticality and castability indexes, leading to a ranking of alloy compositions.
Figure 1. European CRMs assessment from 2011 to 2023.
Figure 1. European CRMs assessment from 2011 to 2023.
Figure 3. Novel alloy design and development strategy for innovative aluminium alloys.
Figure 3. Novel alloy design and development strategy for innovative aluminium alloys.
Figure 5. Die soldering index in several die casting alloys.75
Figure 5. Die soldering index in several die casting alloys.75

List of figure names:

  • Figure 1. European CRMs assessment from 2011 to 2023.
  • Figure 2. Classification of aluminium forming processes used in Audi Q8 BIW structure; adapted from Ref 30.
  • Figure 3. Novel alloy design and development strategy for innovative aluminium alloys.
  • Figure 4. Solidus temperatures for an aluminum-4 wt pct iron-X system.74
  • Figure 5. Die soldering index in several die casting alloys.75

7. Conclusion:

Summary of key findings:

A new theoretical and systematic approach has been developed to design lightweight aluminium alloys for the automotive industry with low content of CRMs, with adequate processability and good mechanical performance. The developed procedure consists of defining indexes that consider the content of critical raw materials and the main parameters influencing the processability of alloys produced by casting processes.

The research provides a framework for designing sustainable aluminium alloys by minimizing reliance on critical raw materials. It has both academic significance (integrating criticality into alloy design) and practical implications (developing alloys suitable for automotive HPDC applications). The multi-objective approach allows for a balanced consideration of performance, processability, and resource sustainability.

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9. Copyright:

  • This material is a paper by "Osama Asghar, Mattia Franceschi, Paolo Ferro and Franco Bonollo": Based on "A NOVEL ALUMINIUM ALLOYS DESIGN STRATEGY FOR LOW USAGE OF CRITICAL RAW MATERIALS AND HIGH CASTING PROCESSIBILITY FOR AUTOMOTIVE APPLICATIONS".
  • Source of paper: https://doi.org/10.1007/s40962-024-01502-6

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