Development of a new methodology to use recycled Secondary Aluminum substituting primary A356 aluminum alloy in safety components in low pressure technology

摘要

FAGOR EDERLAN and MAPSA members of Fagor Ederlan Chassis & Powertrain Division manufacture safety components such as knuckles, control arms, and wheel rims using primary aluminum alloy, named A356 or AlSi7Mg0,3. Components finally are heat treated by a T6 or T64 reaching final properties.In Low Pressure process, secondary aluminum utilization for automotive cast parts is not possible due to the high rates of Fe and Cu percentages. These elements promote the formation of non-desirable phases in the microstracture reducing the mechanical properties and corrosion behavior.In this project two neutralizer compositions have been developed, avoiding the no desired Fe rich needle-shaped phases (β-Al_5FeSi). Adding these neutralizer alloys it is possible to ensure the mechanical properties and functional behavior of safety parts using a secondary A3 56 alloy containing 0,4 % of Fe. Endurance test on components has been carried out to analyze the feasibility of the process.A cost study was also carried out to compare the costs of primary or secondary aluminum alloy, in order to make cost-effective the whole process.