European collaborative research and innovation project led by a multi-disciplinary consortium coordinated by Fagor Ederlan.

RADIUS project will develop automotive brake discs based on recycled aluminium alloys.

Project .

RADIUS ” Recycled automotive components by upgrading metallic scraps “

RADIUS is a European collaborative research and innovation project led by a multi-disciplinary consortium coordinated by Fagor Ederlan.

RADIUS project will develop automotive brake discs based on recycled aluminium alloys.

Aluminium (chisps, dross,..) and silicon (fines, photovoltaic waste,…) metal scraps are recycled efficiently to achieve an ecological aluminium brake disc.

The project seeks to enable the production of car brake discs from Al-Si scraps, under the assumption that Al-Si based car brakes are destined to replace the currently main stream Fe-alloy based ones, mostly in electric vehicles (EV).

Within RADIUS project, aluminium brake discs will be produced by low pressure die casting (LPDC). Low pressure die casting is a competitive casting method, where a ceramic tube is connected from the furnace of melted metal, to the steel die above it. The furnace it is pressurized to fill the part by forcing fluid up by the sprue. Once the casting has solidified the air, pressure is reduced allowing the rest of the metal still in liquid form in the tube to recede back into the furnace.

The main objective of this project is the fabrication of innovative ecological aluminium disc with the maximum level of recycling.

Weight reduction

Increase the resource efficiency

Reduce GHG’s emission

Decrease energy consumption

Improved end-of-life products

Contribute circular economy

Partners .

  • FAGOR EDERLAN, S.COOP (Coordinator)
  • BEFESA Aluminio S.L.
  • Instytut Metali Niezelaznych, IMN (Institute of Non-Ferrous Metals)
  • Bay Zoltan Nonprofit Ltd. for Applied Research
  • Fundación Tecnalia Research & Innovation
  • Leiden University
  • INNSIGHT srl

Workpages .

2018 2019 2020 2021
WP 0 - Feasibility study0%
WP 1 – Project management0%
WP2 – Material characterization0%
WP 3- Up-scaling of the best performance samples0%
WP 4 – Validation of the prototypes at real environment0%
WP 5 – Electrochemical approaches to environmental problems in the process industry0%
WP 6 – Life cycle assessment0%
WP7 – Educational, training and dissemination0%

WP 0 - Feasibility study

The Feasibility study intends to assess the technical, legal and economical viability of the project. The feasibility study (WP0) will be carried out during the first 6 months. The whole WP will be developed, and the tasks are: Business Environment Analysis, Business Model, Stakeholder Engagement, Implementation Plan, IPR Management and Exploitation risk management.

WP 1 – Project management

Management of the project, including communication and dissemination activities, interaction towards th KIC and the EIT. This WP will be developed during all the project. The tasks are: Project administration: The administrative and financial management of the Project, and the Project management.

WP 2 - Material characterization

The WP2 will start at Month 3 (Materials characterization) with the scraps study for wastes, sub products of different sector (photovoltaic, automotive, metallurgy, WEEE, etc.) and characterization of the scraps and development of the most efficient recycled methods to obtain aluminum, silicon metal and magnesium from them. The tasks are: * Scraps characterization (Aluminum, Magnesium and Silicon), leaded by BEFESA; * Mixtures characterization: Comparison of the performance of recycled samples with non-recycled samples, led by INNSIGHT; * and the Determination of the optimum recycled materials ratios of the mixtures, led by INNSIGHT.

WP 3 - Up-scaling of the best performance samples

In October of will test WP3 Up-scaling of the best performance samples led by SKAWINA. The other two tasks (Test of the selected optimum mixtures of recycled materials, and Selection of the mixtures of recycled materials with better properties to build-up real prototypes) will be performed in 2019 and 2021.

WP 4 – Validation of the prototypes at real environment

The objective of this WP is to validate the use of recycled materials in the production of current aluminium disk brakes.

WP 5 – Electrochemical approaches to environmental problems in the process industry

WP5 will be led by BAY ZOLTAN. It consists in the electrochemical approaches to a sustainable protective post-treatment of automotive components (brake discs) at industrial level due to aluminum alloys need to be protected and current anodized method is not environmental friendly.

WP 6 – Life cycle assessment

The objective of this WP is to study the environmental benefits of this project. It will be developed in 2019 and 2020. WP6 Life cycle assessment will be carried out during these 2 years. This LCA will be carried out considering WP3 and WP4 results but it will be optimized with industrial data to be as much as comparable with industrial process. WP3 and WP4 are the main important technical WPs that will be supposed and strong effort during 2 years and will consists in the up-scaling of the best performance sample and Validation of the innovative RADIUS prototype at real environment.

WP 7 – Educational, training and dissemination

Transversal task of dissemination and Communication will also start with the creation of the project website (WP7). All partners will be involved in communication activities through their own channels to support and strengthen the dissemination. WP7 will start with training activities in 2019 (Workshops, Professional training and e-learning modules).

Documents .

Deliverable template
341.00 KB 547 downloads
Deliverables December 3, 2019 Download
Analysis and tests of aluminium alloys from upgrading metallic scraps for recycled automotive components
2.95 MB 285 downloads
Dissemination material November 14, 2019 Download
The Treatment of Liquid Aluminium-Silicon Alloys
83.50 KB 20 downloads
e-learnings August 4, 2020 Download

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