Low Carbon Footprint Aluminium Components for E-Mobility

In the fast-evolving E‐mobility transformation, the circular economy is one of the key factors to make Europe carbon neutral by 2050, together with sustainability, achievable only with a synergic approach, from raw material choice to recycling, through product design for re‐purposing. Secondary aluminium alloys have a twenty times lower carbon footprint than primary metals, leading to significant CO2 savings. Their properties can satisfy engineering targets through optimized product design. Adopting a smart system layout, in which functions are assigned to assemblies, some of the low‐end mechanical properties of secondary alloys can be offset. Design for easy disassembling can then guarantee a selective re‐purposing and, finally, an environmentally friendly recycling of components. Innovative products in this field have been developed and successfully produced by means of an optimized high-pressure die casting (HPDC) technology, adopting low carbon footprint raw materials supplied in alternative to ingot format. In this work, the characterization of a component for e-mobility has been conducted, evaluating both the characteristics of the scrap alloy used to produce the castings and the casting itself. The results demonstrate a fine and high-quality microstructure of the casting, proving the feasibility of the production process using exclusively scrap alloy.