Use of post-consumer scrap in aluminium wrought alloy structural components for the transportation sector

Kristian Martinsen (SINTEF Raufoss Manufacturing), Sverre Gulbrandsen-Dahla (Gjøvik University College)

CHALLENGE - This paper discusses the aspects of possible use of postconsumer scrap in high-end products based on aluminium wrought alloys, describing results from the EU FP7 Project “SuPLight”. Changes to the material tolerances, reverse logistics and novel sustainable business models are key elements for a sustainable use of post-consumer scrap in high-end structural components based on wrought alloy aluminium.

SOLUTION - In this project, a generic framework for multi-scale and multi-disciplinary simulation and optimization was developed in SuPLight. ModeFRONTIER has been used as an engine for combined optimizations of the different plug-ins. These were used for combined weight/performance and life cycle optimization through multiple simulations with step-wise parameter optimization. Abaqus, Forge3D, VASP, LSDyna, LS-OPT and Simapro are some of the background software used in the plug-ins. The case workpiece is the Front Lower wheel suspension Control Arm for the GM Epsilon platform for mid-size cars (such as Opel Insignia) in North America and Europe. 








BENEFITS - The project developed novel aluminium technology prepared for post consumer scrap recycling of aluminium to high-end wrought alloys. The final results after optimization with modeFRONTIER show an improvement to 82,67% of the present control arm.