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<p>Much of the aluminum shape castings for critical automotive structures are made of high-carbon-footprint primary aluminum alloys via high-pressure die casting. With the rapid growth of mega and giga aluminum castings for electric vehicles and the need for high integrity cast products, there is a dire need to reduce carbon footprint and energy usage. Advances and developments in sustainable shape casting of aluminum automotives structures are reviewed. Specifically, (i) a newly developed low-carbon-footprint cast aluminum alloy that is made of 100% selected post-consumer scrap; (ii) critical melt cleanliness means to control oxide reduction and avoidance for high scrap charge melting; (iii) and a high-volume rheocasting process resulting in high strength and integrity castings.</p> Graphical Abstract <p></p>

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Sustainable Pathways to Produce Aluminum Structural Castings

  • 期刊论文

  • 发表日期：

    2025年9月15日

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  • Qigui Wang,
  • Jianfeng Wang,
  • Jason Coryell,
  • Diran Apelian

摘要

Much of the aluminum shape castings for critical automotive structures are made of high-carbon-footprint primary aluminum alloys via high-pressure die casting. With the rapid growth of mega and giga aluminum castings for electric vehicles and the need for high integrity cast products, there is a dire need to reduce carbon footprint and energy usage. Advances and developments in sustainable shape casting of aluminum automotives structures are reviewed. Specifically, (i) a newly developed low-carbon-footprint cast aluminum alloy that is made of 100% selected post-consumer scrap; (ii) critical melt cleanliness means to control oxide reduction and avoidance for high scrap charge melting; (iii) and a high-volume rheocasting process resulting in high strength and integrity castings.

Graphical Abstract