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Challenges • Carbon Reduction

Near Zero Carbon Castings!

Aluminium is infinitely recyclable, which is a key to circular manufacturing, but it carries a higher CO2 content than other metals, particularly steel. The easy answer to this conundrum is to use near zero carbon recycled aluminium, but as secondary alloys are inherently weaker than primary aluminium, this is not straightforward.

Sarginsons only uses hydro-electric primary aluminium, but has also developed unique grain refining technologies that strengthen recycled aluminium, allowing it to be used in any application, whatever the TYE demands. So, secondary aluminium can be used in the same, strength related applications as primary aluminium, but with a near zero carbon burden. Facilitating full circular manufacturing.

In 2024 Sarginsons secured £3m of grant funding to perfect a new recycled aluminium alloy that, thanks to enhanced grain refinement negating iron and oxide contaminants, will be as strong or stronger than primary aluminium.

Zero Carbon Casting

No one would associate aluminium foundries with zero carbon but that is the ambition at Sarginsons. Already using hydro electric aluminium, Sarginsons feels it can go further, by refining the grain structure, negating iron and oxide contamination, of recycled aluminium to reduce carbon to less than 0.5 ton per ton. Not zero, but with hydrogen and direct renewable energy, it is just a matter of time.

Not Just Recycling

True zero carbon is not just about the manufacturing process it's also  about reusing and repurposing components. To this end Sarginsons has initiated the use of QR codes that not only detail the exact alloy composition but also the processes used on the alloy, to give true traceability. This allows introduction of recycled aluminium components directly into the manufacturing process.

The PIVOT Grant

PIVOT is a £6m, 3 year research program based at Brunel University, with 11 collaborators from five countries, led by Sarginsons. A key focus of the research is to elevate the mechanical properties of recycled aluminium, through treatment with rare earth additives, and to ensure that aluminium components are fully traceable.

Key Points

  • Unique, near zero carbon alloys
  • Enhanced strength recycled aluminium.
  • Potential use in castings for aerospace
  • Reuse as well as recycling scheme
  • Lower cost and lower carbon

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Technology Cancels Carbon

Sarginsons is committed to zero carbon aluminium casting, which it's £3m Innovate grant, researching the improvement trace rare earth metals make to iron and oxide contamination This will be a gamechanger.

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