Advanced Grain Refinement for 100% Recycled Structural Aluminum Vehicle Castings
BCAST's advanced grain refinement technology enables the use of 100% recycled aluminum for structural vehicle castings. By overcoming mechanical defects in secondary alloys, it supports the production of lighter, sustainable automotive components, reducing embedded carbon emissions by up to 95%.
Overview
The advanced grain refinement technology developed by BCAST at Brunel University London enables the use of 100% recycled aluminum in high-performance structural automotive castings. By overcoming the mechanical weaknesses and casting defects typically associated with secondary aluminum alloys, this technology facilitates the transition toward a circular economy in vehicle manufacturing. It allows manufacturers to produce structural components that are up to 30% lighter than traditional steel equivalents while maintaining rigorous performance standards, significantly reducing both weight and the carbon footprint of automotive production.
Technical specifications
The technology centers on advanced grain refinement and liquid metal engineering, which allow for:
- Effective microstructural control during the solidification process.
- Improved castability of a wide range of aluminum-silicon alloys.
- Elimination of common casting defects such as hot-tearing.
- Enhanced tensile strength, ductility, and homogeneity in mechanical properties across complex components.
- Capability to produce thin-wall cast structures using recycled aluminum, even with higher impurity levels.
Technology readiness level
The technology is currently in the development and demonstration phase. It is a core component of the multi-partner PIVOT project, which is actively working to integrate these refinement techniques with AI-driven casting simulation and design software to enable industrial-scale adoption for structural components like chassis systems and subframes. This corresponds to a TRL of 6.
About Brunel University London
Brunel University London is a comprehensive public research university in West London with a campus-based community and an applied, industry-engaged ethos. Co-located labs and a science park adjacent to campus provide space for collaborative R&D, while proximity to Heathrow and major transport links makes partnering and pilot deployment straightforward. A strong placement tradition and professional practice pathways connect companies with student and alumni talent for internships and recruitment. Research is backed by competitive funding from UK Research and Innovation councils and Innovate UK, with additional support from national health research bodies. A dedicated technology transfer office manages IP, licensing, and spinouts, and enterprise programs support SMEs and corporate innovation.
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