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Improved Durability Assessment for Lightweight castings

Increased use of recycled aluminum is important for sustainable vehicle production but brings challenges, as defects can reduce service life. Traditional methods may therefore lead to conservative assessments. DuraCast develops guidelines that combine fatigue analysis and fracture mechanics to improve defect tolerance.

The objectives of the prestudy are summarized as follows:

  • Map industry challenges, needs, and opportunities related to the increased use of recycled aluminum.
  • Conduct an in‑depth state‑of‑the‑art (SOTA) review through a comprehensive literature study.
  • Organize a workshop to disseminate insights from the pre-study and gather additional input from industry.
  • Prepare a full-scale project proposal for the upcoming FFI call (FFI Circularity 2026).
  • Carry out mechanical testing, including fatigue and fracture mechanics experiments.
  • Conduct a master’s thesis project aligned with the goals of the pre-study.

To support the mapping of industrial challenges, needs, and opportunities, a reference group has been established. The participating companies are:

  • Volvo Cars Corporation
  • Scania CV AB
  • Volvo Trucks
  • ZEEKR Technology Europe AB
  • Fundo Components

Summary

Project name

DuraCast - Prestudy

Status

Active

RISE role in project

Coordinator

Project start

Duration

6 months

Total budget

399766 SEK

Partner

Linköpings University, Husqvarna, Volvo Cars (reference group), Scania CV AB (reference group), ZEEKR Technology Europe AB (reference group), Fundo Components (reference group)

Funders

FFI

Project members

Supports the UN sustainability goals

9. Industry, innovation and infrastructure
Erik Dartfeldt

Contact person

Erik Dartfeldt

Forskare

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Torsten Sjögren

Contact person

Torsten Sjögren

Forskare

+46 10 516 52 49

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