National Projects
Development of technology for extrusion of sections from ultra-durable AlMgSi(Cu) alloys (EXALCO)
Title: Development of technology for extrusion of sections from ultra-durable AlMgSi(Cu) alloys
Acronym: EXALCO
Programme: TECHMATSTRATEG
Project value: PLN 17,068,748.82
Contribution from national funds: PLN 12,483,402.94
Co-financing for Łukasiewicz–GIT: PLN 1,491,950.00
Project financed by the National Centre for Research and Development under the Strategic Research and Development Programme “Modern materials technologies” TECHMATSTRATEG
Implementation period: 2021 – 2024
Executive Agency: National Centre for Research and Development
Consortium:
- Łukasiewicz Research Network – Institute of Non-Ferrous Metals
- Stanisław Staszic AGH University of Science in Kraków
- Albatros Aluminium sp. z o.o.
- Łukasiewicz Research Network – Upper Silesian Institute of Technology
- Łukasiewicz Research Network – Industrial Automotive Institute
Project Manager for Łukasiewicz – GIT:
Marek Węglowski, BEng, PhD
Tel.: 32 33 58 236
E-mail: marek.weglowski@git.lukasiewicz.gov.pl
Objective:
The project concerns the development and preparation for the implementation of a new technology of extrusion of sections from ultra-durable AlMgSi(Cu) alloys, intended for lightweight structural components in the automotive segment and the transport industry.
The aim of the project is to design chemical compositions of AlMgSi(Cu) alloys in conjunction with innovative constructional and technological solutions of the extrusion process based on low-temperature thermal plastic working on the press run and continuous ageing in a controlled temperature field.
Products made of AlMgSi(Cu) alloys for the automotive segment are mainly produced using rolling technology, while the process of industrial extrusion with thermal plastic working is a novelty on a national and global scale. The project assumes obtaining tensile strength for sections at the level of min. 460 MPa (battery housings and supporting components, enclosures – with simple shapes), min. 430 MPa (battery housings and supporting components, enclosures – with complex shapes) and min. 370 MPa with a percentage reduction of area of min. 12% (controlled compression zone) – while ensuring economically acceptable efficiency of the extrusion process at the level of min. 12-13 m/min. At the same time, a high degree of uniformity of mechanical properties of AlMgSi(Cu) sections aged continuously in a controlled temperature field (temperature gradient max. 2-3ºC) – gradient of mechanical properties 2-3%. The profiles will be subjected to tests of weldability and suitability for the automotive industry.
The proposed solutions will have a major impact on the development of the electromobility market in Poland, and lightweight and high-strength AlMgSi alloy profiles with the addition of Cu will be strongly competitive for products made of steel.
Projected annual revenues in the first 5 years of implementation are at the level of approx. PLN 6.35 million, which will allow to achieve the level of co-financing for the project just over 2 years after its completion.
