MaReAl

Manufacturing of Al-MMC brake discs from recycled Al-Si alloys.

Introduction

Aluminium-based composites are promising candidates for replacing cast iron in heavy automotive components, like brake discs.

The project aims to include recycled aluminium alloys in producing metal matrix composites for brake discs.

In composite materials, the aluminium alloy is the matrix reinforced with hard particles, like silicon carbide. These composites have suitable mechanical characteristics, and optimisation of the component design further maximises their performance.

The primary industrial need behind the project is the need for lightweight solutions that reduce fuel consumption and emissions in regular vehicles.

Importance

Lightweight solutions for automotive applications are fundamental for several goals: reduction of fuel consumption, emissions reduction, employment in electric vehicles are the main ones.

Continuously updated knowledge about sustainability is nowadays crucial. This project gives the opportunity to acquire knowledge on recycled aluminium alloys in composites to develop lightweight and sustainable products. This knowledge will be relevant for commercial solutions, research strategies, and academic and life-long learning education.

Impact

The project's impact is significant: a 50 % lighter brake disc with the maximum quantity of recycled alloy. The use of recycled aluminium-silicon alloys for MMC production represents an added value in the light of sustainability, increased recycling and reduced raw material losses in metallurgical processes. The use of recycled materials is mandatory to face the sustainability development goals of the next decades.

The project ensures efficient use of metal scrap and increased collaboration between universities, research institutes, and industry.

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