REALCAR

REALCAR

This is a project led by JLR to explore ways to increase the use of recycled aluminum in automobile manufacturing. The overall goal of the project is to develop technologies and processes that will enable lightweight automotive body structures to be built using aluminum sheet derived from lower-cost, energy-efficient, recycled sources, in line with JLR’s Environmental Innovation (EI) strategy to reduce the CO2 footprint of manufacturing premium cars. REALCAR is targeting 75% recycled content for automotive aluminum sheet, including about 50% from manufacturing scrap and 25% from various post-consumer sources. REALCAR addresses the sourcing of aluminum scrap by exploring infrastructure and recycling approaches at the manufacturing facilities of JLR and its Tier 1 suppliers. The project aims to drive progress towards a streamlined logistics/supply chain to facilitate closed-loop returns of aluminum scrap, which not only reduces the carbon footprint of the material but also provides a low-cost source. The project has also investigated potential scrap sources from non-automotive sources and end-of-life vehicle waste; this investigation has identified a number of future opportunities. REALCAR evaluated over 20 different sheet chemistries and processes, and developed two compositions based on commercially available aluminum scrap sources, with a view to replacing the sheet grade that accounts for the majority of aluminum structural sheet used in JLR body construction in the next generation of JLR products.

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