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Challenges • Carbon Reduction

Zero Carbon Castings?

Aluminium is infinitely recyclable, which is a key to circular manufacturing, but it carries a higher carbon content because it's production is energy hungry. The easy answer is to use recycled aluminium but, as it's inherently weaker than primary aluminium, Sarginsons had to develop a stronger recycled aluminium alloy. 

Sarginsons developed a unique grain refining technology to return recycled aluminium's strength to that when new, so it can be used in any application, whatever the mechanical demand. In 2024 Sarginsons secured £3m of grant funding to perfect and validate this new recycled aluminium alloy. 2026 should see the launchof this huge step forward to a carbon free world. and a huge reduction in destruction wrought by extractive mining on the environment. 

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 yet, but it is felt this 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 of recovered parts, but also the processes used on the alloy. 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 Is Carbon Free

Sarginsons is committed to zero carbon aluminium casting, which it's £3m Innovate grant, researching the improvement additives make to iron and oxide contamination in aluminium castings is a gamechanger.

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