Digitization and networking at the heart of the "Green-Al-Light" joint project to improve the CO2 footprint for lightweight aluminum construction

GreenAlLight Aluminium Gussteil
(PresseBox) ( Wuppertal, )
Alongside energy-efficient drives, lightweight materials are a key to reducing environmental impact and increasing resource efficiency in mobility. For structural components, high-strength wrought aluminum alloys can make an important contribution. However, it is important not only to consider the potential for CO2 reduction in vehicle operation. Of increasing importance are the considerable efforts required to manufacture the components - and here the use of recycled aluminum can save up to 95% of emissions compared with the use of primary material.

With the aim of establishing an optimized process chain, particularly for high-strength automotive structural parts using recycled aluminum, well-known companies from the entire supply chain have joined forces and launched the "Green-Al-Light" project, which is funded by the German Federal Ministry for Economic Affairs and Energy. The focus is on the increased use of end-of-life scrap from the automotive sector. First of all, these scraps are to be separated as purely as possible by means of a highly modern sorting technology at cleansort GmbH and Clean-Lasersysteme GmbH. Adapted alloys from TRIMET Aluminum and casting and forging technologies from Otto Fuchs KG will be used to develop overall CO2-optimized and cost-efficient manufacturing processes - and finally the manufactured components will be validated and used by the vehicle manufacturer Audi AG. FAU Erlangen-Nuremberg accompanies the processes with highly developed testing and measurement technology.

The goal can only be achieved by taking a holistic view of all process steps and their interactions, in close networking of all those involved. State-of-the-art digitization technologies are used for this purpose, which are lead-developed and provided by Matplus GmbH. "By modeling material properties as well as energy and material flows, we support the entire process chain. In addition, we are developing specialized evaluation tools for technical project data for this purpose," explains Dr. Bernd Koch, project manager at Matplus.

For more information on the joint project, visit www.green-al-light.de
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