BCAST develops aluminium alloys and casting techniques for lightweight vehicles

The Brunel Centre for Advanced Solidification Technology (BCAST), a global leader in metallurgical casting research centre at Brunel University London, has developed an advanced aluminium alloys and casting techniques for lightweight aluminium cars and trains.

BCAST is working with foundry partner Sarginsons Industries and others on the Lightweight Energy Absorbing Aluminium Structures for Transport (LEAAST) project for developing cast aluminium alloys, the recycling of aluminium alloys using melt-conditioned direct chill casting, and the overcasting technology.

For this, two aluminium alloys have been developed and successfully tested. The LEAAST project involved an investment of £2.2m, which began in May 2015. The project is being funded by Innovate UK, and involves 10 industrial partners and research institutions led by Jaguar Land Rover.

“The new 6xxx series wrought alloy can provide yield strength and elongation of more than 500 MPa and 10%, respectively. The new 3xx series cast alloy is about 3 times lighter than steel and, compared with previous alloys, has yield strength of 310 MPa, ultimate tensile strength of 365 MPa and elongation of 10%.”

“This provides a ratio of strength to density that enables parts made from these alloys to absorb the required stresses and deform in a controlled manner under impact,” as reported.

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Anthony Evans, Managing Director at Sarginsons Industries in Coventry, said: “Lightweight crash management systems are of increasing importance for most forms of ground transport. While at present many automotive original equipment manufacturers have advanced aluminium automotive body designs, they still depend on steel for bumper beams.”

“Delivering fully sustainable and high-ductility alloy is critical for providing the automotive industry with light weighting options to counter the higher-weight battery and hybrid vehicle base loads.”