A groundbreaking research initiative in the Midlands is set to revolutionize the automotive industry by utilizing 100% recycled aluminum to create lighter vehicle components. Coventry-based Sarginsons Industries, in collaboration with Aston Martin and supported by a $6.72 million matched grant from the Advanced Propulsion Centre and Innovate UK, is spearheading the Performance Integrated Vehicle Optimisation Technology (PIVOT) project.
A Game Changer for Sustainable Vehicles
This innovative project aims to significantly enhance the sustainability, weight, performance, and cost-effectiveness of new vehicles. The use of recycled aluminum marks a pivotal shift in sourcing materials for automotive manufacturing, allowing for lighter, stronger components that enhance overall vehicle performance.
AI-Driven Design Innovations
Altair, a leader in computational intelligence, will partner with Sarginsons to develop advanced software that employs AI to create organic designs for new chassis components based on an existing Aston Martin model. This automated, simulation-driven design process will enable rapid development and cost reduction, while ensuring that each component is both lightweight and robust.
By simulating the varying mechanical properties of parts, the software will intelligently place materials where they are most effective, resulting in a potential 30% reduction in chassis weight without compromising structural integrity.
A Sustainable Future for Aluminum Sourcing
The PIVOT project also focuses on enhancing the sustainability of aluminum sourcing by replacing high-carbon, primary aluminum materials with fully recycled aluminum. This initiative could reduce the carbon footprint of aluminum-cast components by up to 95%, significantly contributing to the automotive industry’s net-zero goals.
Sarginsons will collaborate with Brunel University and metal recycling experts GESCRAP to develop grain structure refinement techniques that address impurities found in recycled aluminum, ensuring that the final components meet safety and performance standards.
Building a New Recycling Network
Part of this transformative project involves establishing a UK-based recycling network for secondary aluminum, which aims to decrease reliance on finite primary aluminum sources. Currently, primary aluminum production generates approximately 12 tonnes of carbon emissions per tonne of aluminum. In contrast, 100% recycled secondary aluminum can reduce emissions to less than 0.5 tonnes per tonne, representing a remarkable 95% reduction.
Sarginsons is leading this ambitious research effort alongside key partners, including Aston Martin, Altair, Brunel University London, and GESCRAP. With a secured grant of around £3 million from PIVOT, Sarginsons is poised to expand its workforce and acquire new equipment to support this pioneering initiative.
