AluScaL - Lightweight construction with high-strength aluminium-scandium alloys for hydrogen mobility, aviation and vehicle construction
The planned switch to hydrogen as an energy supplier in aviation, rail vehicles, shipping and road transport requires constant innovation in order to play a leading role in global competition. This also includes the further development and qualification of new material solutions. As part of the AluScaL project, which is funded by the Federal Ministry for Economic Affairs and Energy and supervised by Project Management Jülich, the potential of scandium (Sc) as a strength-enhancing alloying element in aluminium alloys is to be investigated and demonstrated using the example of an application from hydrogen mobility.
Scandium is an alloying element that has been known for some time and can greatly improve the mechanical properties of aluminium alloys, particularly their strength properties. The high price of scandium and the monopoly position of individual countries in its supply have so far prevented the widespread use of aluminium-scandium alloys (Al-Sc alloys).
In recent years, Canadian, Australian and European initiatives have succeeded in opening up new deposits and developing new process routes for scandium extraction. For example, what is believed to be the largest deposit of rare earths (including scandium) was recently discovered in Kiruna in northern Sweden. This is expected to lead to a significant reduction in the current price of scandium, resulting in a wider range of applications.
The aim of the AluScaL project is to demonstrate the process chain from raw material extraction, alloy development and production through to the component and to prove its suitability for lightweight construction and hydrogen applications.
The DLR Institute of Vehicle Concepts (DLR-FK) is the consortium leader and is responsible for the mechanical characterisation, the investigation of hydrogen suitability and the development of application-oriented design and simulation methods for the newly developed Al-Sc alloys. The Helmholtz-Zentrum Berlin (HZB) is developing new alloy variants made of aluminium and scandium and carrying out in-situ microstructure analyses for this purpose. The Al-Sc-Master-Alloy is provided to the consortium by the company Rio Tinto Alcan International from Canada, which is involved as an associated partner. Rio Tinto is also supporting the project with its expertise in the field of alloy development.
Gränges Powder Metallurgy GmbH is investigating spray compacting for the production of semi-finished products and powder. The companies Rosswag GmbH and LEIBER Group GmbH & Co. KG, the actual component production takes place. At Rosswag GmbH, the valve is additively manufactured with processing parameters suitable for the alloys and at the LEIBER Group, a forging process adapted to the new material is used for production. A hydrogen valve from Argo-Anleg GmbH serves as a pilot application for the technology, which will also be trialled there once it has been manufactured. Gühring KG is developing appropriate cutting tools for the final machining process. Other associated partners supporting the project are Recaro Aircraft Seating GmbH & Co. KG and Liebherr-Aerospace Lindenberg GmbH are also supporting the project. The partners Recaro Aircraft Seating and Liebherr-Aerospace are focussing on the respective application and technology transfer to other industries.
This broad-based and efficient consortium makes it possible to fully analyse and evaluate the alloy systems and assemblies developed. In this way, new applications can be developed and the potential of Al-Sc alloys can be fully utilised across all industries. In addition, an important contribution is made to technological leadership in the field of hydrogen technologies in Germany.
