FLAMINGo will propose a novel industrial manufacturing route for the efficient production of high performance lightweight Aluminium composite materials thanks to a novel metallurgical and forming combined approach for making automotive parts. The intensification of use of the Aluminium composites will be driven mainly by the battery-electric vehicle (BEV) technology that are forcing automakers to look for innovative ways to lightweight the vehicles. The goals of FLAMINGo will be related to the manufacturing of a strengthened Aluminium Metal Matrix Composites Al-MMC with elevated properties (+200% strength and +30% stiffness) compared to current Al alloys used in automotive. FLAMINGo will provide engineering solutions to substitute steel components in BEV automotive parts and achieve a substantial reduction of weight (up to 20%).

To reach these goals the project will target the following development steps at prototype and full scale:

• The production of nanoparticles concentrated masterbatches of Al-MMC, via solid state mechanical alloying, to assure a complete dispersion of the nanoparticles in the Al metal before inoculation in the melt;
• Casting of Al-MMC components by inoculating the masterbatch in an Al melt, and homogenized by ultrasonication and electromagnetic stirring systems;
• Production of smaller components (brackets and connectors) by Low Pressure Die Casting LPDC and bigger components, like subframes, by Green Sand Casting to demonstrate broader feasibility and applicability of Al-MMC;
• Extrusion of cast billets for making profiles for the body frame;
• Identification of the welding techniques for joining Al-MMC components, and assessment of the application via TIG, GTAW and RSW;
• Use of these components for substitution of steels and aluminium parts in electric vehicles, validation of components estimated service life and installation on vehicles;
• Recycling of Al-MMC components supported also by the use of secondary aluminium in the formulation.