The EU Horizon project "FLAMINGO" (acronym for "Fabrication of Lightweight Aluminium Metal matrix composites and validation In Green vehicles") has already received two awards. In 2022, the project website received the EU Web Award and in 2024 "FLAMINGO" won the Eco Design Contest of the Spanish CONAMA Foundation. But the zenith has not yet been reached. With the commercialization of the technology, a cumulative turnover of 25 million euros is expected in five years. The "FLAMINGO" project has a project volume of 7.7 million euros. Ten partners from nine European countries are behind it to research sustainable metal matrix composites that exceed conventional aluminium alloys in terms of strength, but at the same time have a low weight and thus ensure increased energy efficiency in electric vehicles, for example. In a first step, two components in the project for an electrically powered municipal vehicle - steering knuckles and rear wheel frame - were designed with topology optimization in order to adapt the material layout to specific requirements and operating conditions. The first castings were preceded by extensive preliminary tests on ultrasonic treatment of the melt in order to reduce the harmful effects of any contaminants and to distribute the nanoparticles used homogeneously. In the casting process of the prototypes, the team of researchers used sand molds that were produced using 3D printing. The practical test for the innovative composite materials as built-in components in a real vehicle was clearly positive. The topology-optimized and nanoparticle-reinforced aluminum castings are in no way inferior to the steel-based alternative in terms of their load-bearing capacity, but have a weight that is up to 60% lower. For electric vehicles, this means increased energy efficiency, especially since recycling tests also show optimization potential from a resource-related point of view.
 |
 |
 |