Eurecat is the leading technology centre in Catalonia, and the second largest private research organization in Southern Europe.
It manages a turnover of 50M€ and 650 professionals, is involved in more than 200 R&D projects and has a customer portfolio of over 1,500 companies.
In addition to being the project coordinator, EURECAT will conduct the basic research to develop the partial recycled alloys and will assist aluminium producers in defining the procedure to manufacture the alloy and the die casting and stamping transformers about the best processing conditions.
EURECAT will also develop a model to assist the design of tools and set up of the production process for the new developed alloys and models to correlate composition and mechanical properties. The role of EUT is rounded off by its support to industrial partners by providing additional tools: LCA and LCC of the newly developed alloys, market analysis, and by helping them to define the best IPR protection solution and commercial strategy to exploit the results obtained in SALEMA project.
GESTAMP is an international group dedicated to the design, development and manufacture of metal automotive components.
The Group specializes in developing innovatively designed products to achieve increasingly safer and lighter vehicles, thereby reducing energy consumption and environmental impact.
GESTAMP will be involved in setting up of the stamping process, validation of new alloys and production of SALEMA components as well as responsible for the implementation of the hot stamping pilot plant in their facilities.
They will use the pilot plant to validate the new aluminum alloys through the manufacturing, by hot stamping, of demonstrator at full industrial level.
Łukasiewicz Research Network – Institute of Non-Ferrous Metals (IMN) a research centre of the Polish non-ferrous industry.
Complex activities cover all stages of metallic materials production: from ore treatment to technologies for production of modern product meeting all environmental standards.
The center in Skawina carries out research on advanced technologies of forming Al and Mg alloys.
The scope of IMN’s work will focus on research on the influence of inclusions from various scrap shares and phases formed from micro-additives on the quality and properties of aluminum alloys using the Prefil Footprinter® device.
Together with the consortium members, IMN will participate in the design of new aluminum alloys for casting, extrusion and stamping processes, with a low silicum and / or magnesium content and with the proper use of components other than these Critical Raw Materials.
Dating back to 1222, the University of Padova (UNIPD) is one of the world’s oldest universities and one of the leading Universities in Italy with a long tradition and consolidated reputation for scientific excellence.
The Department of Management and Engineering covers the engineering, technological and economic competencies needed to develop new products, materials, and production processes favouring technical management and economic profitability.
One of the strongest research areas is related to light alloys and foundry processes.
The role in the project is related to the development of innovative Aluminium alloys (both wrought and casting) for electric automotive applications, based on a low content of Critical Raw Materials.
From thermo-dynamical and thermo-physical models, candidate compositions will be defined and subsequently elaborated and experimentally tested.
ASAS is one of the most remarkable industrial enterprises in Turkey with its 5 state-of-the-art production facilities in Akyazı, Sakarya region and over 2000 employees and export to over 80 countries.
ASAŞ generates solutions and adds value to all sectors where it operates, thanks to its innovative products, technology, R&D center and its services.
ASAŞ provides services for its clients at its Aluminium Profile, Composite Panel, Aluminium Flat Rolled Product, PVC Profile and Roller Shutter production facilities, which are located in a total of 700.000 m² area, of which 400.000 m², is enclosed, in Akyazı and Karapürçek complex.
ASAŞ participates the SALEMA Project mainly to industrialize the developed novel alloy with Critical Raw Material substitution strategy in its aluminium extrusion profiles facility which has a capacity of 75.000 tonnes.
Also, high amount of scrap content will be deployed industrially within the scope of SALEMA.
Raffmetal is today Europe’s largest producer of aluminium foundry alloys using only recycled aluminium, with a production capacity of more than 300,000 tonnes per year, 413 employees and two production facilities located in the north of Italy.
Starting from 2021 Raffmetal has expanded its range of alloys with the addition of SILVAL primary recycled alloys with a low carbon footprint, with the same performance as primary aluminium alloys produced from bauxite, but avoiding the exploitation of mineral resources and further promoting the circular economy, which has always been the company’s core business and is now a key pillar of the new European Green Deal strategy
Raffmetal will play a key role in the study and production of aluminium alloys for electric vehicles.
In line with its core business and the know-how acquired in 40 years of activity, the company will work on the adaptation of industrial plants to produce two types of new aluminium alloys with high quality and developed mechanical performance: structural alloys produced mainly from scrap and structural alloys with low silicon content.
No less important objective will be to develop the pre-treatment that produces the least amount of slag and energy consumption of the scrap used to produce the alloys. This will make it possible to make an effective contribution to reducing the carbon footprint along the entire production chain.
The COMET Group is recycling used ferrous and non-ferrous materials. The group owns its collection and sorting systems, which means that it can make the most of the wealth of used materials available.
Over the years, COMET has established a major diversification strategy that has considerably expanded the scope of its opportunities.
Its research programmes aim to make maximum use of shredder residue.
Thanks to these programmes, COMET now produces fuel for cogeneration units, plastics, industrial sand and even pure copper.
Different qualities of aluminium will be extracted from a Zorba stream from recycling activities of end-of-life vehicles and metallic scraps.
COMET and ULIEGE will work on the characterization of aluminium scrap commonly available. They will perform a manual (handheld XRF supported) selection of different selected high-quality scraps.
Preliminary identification & sorting tests will be implemented on the Pickit prototype. The volumes of alloys provided will allow the realization of fusion tests on an industrial scale.
ULiège (Universite de Liege) is a Belgian University specialized in georesources, mineral engineering and extractive metallurgy through its GeMMe Research Group, member of the Urban and Environmental Engineering Research Unit.
The GeMMe contributes to the development of innovative processes for the efficient management of mineral and metallic resources while providing unparalleled upscaling experience in urban ore characterization and processing.
Through the SALEMA project, ULiège will expand knowledge in aluminium sorting and recycling processes and further develop efficient and sustainable Al alloys using a higher percentage of scrap.
ULiège will notably lead tasks on “scrap sorting system optimisation” with the following objectives :
- Develop a multi-sensor based automated multiclass online robotic sorting system of Al alloys.
- Operate a large-scale pilot campaign for the sorting of up to 150 tonnes of scrap metal to deliver large batches of minimum 30 tonnes of various Al alloys for pilot activities of WP 4, 5 and 6.
- Assess the ability of the new alloys developed within SALEMA to be sorted from scraps streams.
European Aluminium, founded in 1981, is the association that represents the whole value chain of the aluminium industry in Europe, with more than 85 members companies.
We actively engage with decision-makers and the wider stakeholder community to promote the outstanding properties of aluminium, secure growth and optimise the contribution our metal can make to meeting Europe’s sustainability challenges.
Through environmental and technical expertise, economic and statistical analysis, scientific research, education and sharing of best practices, public affairs and communication activities, European Aluminium promotes the use of aluminium as key enabler to achieving sustainable goals, while maintaining and improving the image of the industry, of the material and of its applications among their stakeholders.
European Aluminium will be mostly in charge of boosting SALEMA impact, promoting a beneficial regulatory and policy framework and identifying standardisation potential and contribution to the development of standards.
These tasks will include the organisation of two workshops with the European Aluminium Industry and stakeholders.
In addition, European Aluminium will actively communicate and disseminate SALEMA project results to the aluminium sector and in particular to the members of the recycling division and Automotive and Transport market group, through its internal and external newsletter and presentations at relevant events.
Centro Ricerche Fiat S.C.p.A. is an applied research centre, founded in 1976 as an innovation development pole for Fiat Group companies.
Its main activities are R&D technologies for engines and components, green mobility, research for safe mobility, optics, telematics, new materials, microtechnology and production technologies.
It has more than 850 highly qualified employees.
As end-user, the main role of CRF in the project will be to validate the requirements and critical specifications to be considered for the development of each subsystem for the novel lightweight multi-material structure for the Frontal Pillar demonstrator.
CRF will also contribute in the definition of the alloys main specifications. Furthermore, CRF will play a key role in the project by assisting the consortium in the exploitation of results in the automotive context.
The Spanish Association for Standardization (UNE), is legally designated as the National Standardization Body of Spain since 1987.
It is the national representative and member on the European (CEN and CENELEC), International (ISO and IEC) and Pan-American (COPANT) Standards Organizations, and member of the European Telecommunications Standards Institute (ETSI).
UNE supports SALEMA in all aspects related to standardization, from the start to the end of the project and beyond. Especially, by identifying existing standards, engaging with standardization organizations, identifying standardization potential of project results and promoting the growth of new standards covering SALEMA’s outcomes.
The aim is contributing to increase the impact of the project, especially among industry, society and public authorities.
ESCI is a not-for-profit organisation that empowers scientists and engineers, helping them to communicate with a non-expert audience to bridge the gap between science, technology and society.
ESCI supports national and international research and innovation initiatives in communicating effectively and leveraging their dissemination potential.
In addition to providing up-to-date media training, ESCI has put together a compelling set of dissemination tools specifically with different stakeholders and target audiences in mind.
ESCI leads the communication and dissemination of the project.
During the course of the project, ESCI will identify the communication needs for specific audiences, find and use the channels of communication needed to reach them.
With more than 250.000 Ton of aluminium processed per year and staff of 1000 employees, Profilglass reached a leading position at international level, exporting more than 85 countries worldwide.
Profilglass is a unique entity in the flat rolled product industry as it can perform in-house the entire aluminium cycle, from scrap sorting and processing to finished product.
The main role in SALEMA will be to develop high performance Al alloys in form of coils or sheet designed for stamping of light-weight automotive and electric vehicle applications.
A new alluminum alloy will be developed through an intesive use of recycled scrap and minimizing the use of CRM’s in favour of a more sustainable production process.
ENDURANCE is a direct supplier to OEMs (Original Equipment Manufacturers), with high focus on engine and transmission components. Its product portfolio includes rough and machined aluminium castings (HPDC) and module assembling.
ENDURANCE’s vision relies on achieving and maintaining leadership in technology and product reliability, growing as a complete solution provider of automotive components, staying ahead in a rapidly evolving market.
Its customers include leading car manufacturers such as Volkswagen, Fiat Chrysler Automobiles, Daimler, AUDI, Porsche, BMW and CNH industrial.
ENDURANCE will perform feasibility analysis to re-design and produce High Pressure Die Casting demonstrator in low Critical Raw Material (CRM) content alloys developed within SALEMA.
A dedicated foundry pilot unit will process the innovative alloys, optimizing the internal logistic to prevent low CRM alloys mix with others alloys, the treatment and the melt handling, as well as the casting process parameters , with the goals to provide samples for functional tests and to assess final product’s cost comparison (low CRM content vs state of the art aluminum alloys).
Fagor Ederlan is a world leader in Chassis, Powertrain and Structural components for the Automotive sector.
Our forward-looking strategy is based on innovation, technological development and our values as a cooperative.
Continuous improvement of product such as the lightening and improved performance of components are just part of our offer’s DNA.
FAGOR EDERLAN will provide to SALEMA its long expertise in high-pressure die casting and the availability of industrial scale full equipped facilities at its technology center EDERTEK. EDERTEK in the context of the project will be used to manufacture the final demonstrators of one of the use cases.
The following activities will be carried out by FAGOR EDERLAN:
- adaptation of the existing facilities for the new alloys
- production of a real structural component of high-pressure die casting
- first validation of the parts agreed.
Additionally, FAGOR EDERLAN will also participate and give support in the definition of the requirements for new alloys, as well as in impact, communication and project management activities.
Ford Motor Company began with a staff of 10 in 1903, and has now grown to employ thousands of talented women and men who regularly innovate to deliver a variety of mobility choices.
Our team collaborates worldwide to provide new transportation solutions to our customers.
As a car manufacturer, Ford will validate the requirements and critical specifications to be taken into account for the development of each subsystem for the novel High-Pressure Die Casting shock-tower.
They will conduct:
- Full vehicle CAE analysis and assembly processes
- Complete validation of the full virtual engineering approach
- Demonstration of circular use
FORD will also participate in tasks contributing in the definition of the specifications of the new aluminium alloys, and in management, outreach and exploitation activities.