Nemalloy, a new class of lightweight automotive aluminium alloy bags the prestigious ‘Altair Enlighten Award 2022’

Sumanth Sarkar, a mechanical engineer professor and research scientist Xiaochun Zeng developed an entirely new class of alloys named Nemalloy that combines aluminium and iron to produce a high-strength material at least 35 per cent lighter than a conventional aluminium alloy.

In August, under the Future of lightweighting category of the 'Altair Enlighten Award 2022' recognized the project's potential impact on the industry. The awards, which cooperate with the Michigan-based Center for Automotive Research (CAR), honour innovations that lighten vehicles to save money, increase efficiency, save fuel, and pave the way for a more sustainable automotive future. This unique creation was the result of an effective partnership between McMaster researchers, industrial partner Nemak, and the federal government's CanmetMaterials Technology Laboratory (CMAT).

“Aluminum alloys were innovated for net-shaped castings during our war efforts in the early 20th century and everyone just kind of tweaked them for automotive needs since then. We decided to look at redesigning this material with an eye to what we really need to make these car parts as we move toward decarbonizing the industry,” said Sumanth Sarkar.

Nemalloy (novel lightweight automotive aluminium alloy), which has been dubbed a smart, simple, and sustainable alloy replacement, is expected to appear in a new generation of battery-operated and internal combustion engine cars shortly. Sumanth prepared the next-generation alloy for the market in collaboration with automobile company Nemak, a major global producer of aluminium components for powertrain, e-mobility, and structural applications.

According to the manufacturer, the new die casting alloy will benefit the automotive sector as it looks for creative and affordable solutions to lower vehicle mass and advances the sector's sustainability.

"Nemak's purpose centres on driving lightweighting innovation and technology for the advancement of a more sustainable human mobility. This award reflects our commitment toward contributing to the conservation of the environment and the wellbeing of society,” said Armando Tamez, Nemak’s CEO.

Beyond its lighter weight, Nemalloy also has other advantages for the environment. Due to its unique composition, there is no need for heat treatment to strengthen it, which lowers manufacturing and process maintenance costs dramatically. It is also simple to cast into extensive, thin-walled components and is totally recyclable. The creation of the alloy required a sizable investment from CanmetMaterials, which has had its headquarters at McMaster Innovation Park since 2011.

Sumanth and collaborators are beginning a four-year transdisciplinary collaborative effort to investigate new technologies and alloys for structural vehicle castings in light of his experience with Nemalloy.