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LIFE 4GreenSteel - Excellent Model for High Strength PM Steel parts production by resource and energy efficiency and CO2 and REACH decrease

LIFE16 ENV/IT/000231


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Contact details:

Contact person: Valentina Zampogna
Tel: 0499000189
Fax: 0495089301
Email: valentina.zampogna@tfmgroup.it



Project description:

Background

The production process for high-performance steel components for the automotive industry has a considerable impact on the environment and on human health that could be alleviated with more efficient use of raw materials and energy, and reductions in waste chemicals and greenhouse gas emissions. High-performance steel components, such as gears, are currently produced by a machining technology, mainly due to high requirements in terms of mechanical properties and dimensional stability. The Powder Metallurgy (PM) technology is a sustainable manufacturing process recognised as a green technology and the high mechanical and dimensional requirements above-mentioned could also be theoretically met by means of an innovative Die Wall Lubrication (DWL) compaction stage, in combination with high-temperature vacuum sintering and thermochemical treatment. The DWL compaction process is currently used only in a limited number of applications. It is currently not exploited at an industrial level due to the difficulties of planning, managing and monitoring the productive process.


Objectives

The aim of the LIFE 4GreenSteel project is to demonstrate the feasibility of replacing the traditional energy-intensive and material-consuming machining of wrought metals with a new and innovative High Density Powder Metallurgy (HDPM) technology for the manufacturing of widely-used high-performance steel components, particularly gears for the automotive market.

Specific technical objectives are to:

  • Develop an effective pressing system, operating with the DWL technique, to produce sintered steel parts that have a density greater than 7.3 g/cc and high dimensional stability;
  • Tailoring the high-temperature vacuum sintering stage and development of a reliable case-hardened profile of PM steel by means of the thermochemical treatment Low Pressure Carburising (LPC);
  • Use a chemical composition for steel avoiding harmful alloying elements (nickel), such as nickel, or alloying elements that make the recycling process difficult and ineffective, such as copper;
  • Reduce by more than 70% the lubricant premixed with metal powder, so eliminating the burning stage, increasing energy efficiency and solving related emission problems; and
  • Achieve energy and material saving through the innovative HDPM technology, which has a very high coefficient of material use (95%) and therefore minimises energy input; and
  • The project actions will contribute to the implementation of the Circular Economy Action Plan, the Roadmap to a Resource Efficient Europe, the Directive on Energy end-use efficiency and energy services, and Decision (406/2009/CE) on Energy Efficiency. Furthermore, LIFE 4GreenSteel is relevant to EU policy on sustainable growth and will also provide European enterprises with tools to enhance their competitiveness.

    Expected environmental results: The LIFE 4GreenSteel project expects to achieve the following results:

  • Reduction in use of raw materials by 47.4% compared to the machining baseline;
  • Energy savings of 50% compared to the machining baseline;
  • Strong reduction of cutting fluids lubricants avoiding machining operations;
  • Reduction of metal powder admixed lubricant by 70% compared to the standard PM baseline;
  • CO2 reduction of 49.3 % compared to the machining baseline;
  • Development of an innovative HDPM process to produce a high-performance steel component from 1 200 to 7 500 pieces/day;
  • Development of at least 300 innovative HDPM steel demonstration components that are able to sustain effective surface treatments;
  • Development of at least 300 PM steel demonstration components without copper and nickel as alloying elements;
  • Elimination of dewaxing/burning process for admixed powder lubricant; and
  • Reduction in production cost in respect to the machining baseline.


Results


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Environmental issues addressed:

Themes

Industry-Production - Metal industry
Waste - Waste reduction - Raw material saving


Keywords

raw material consumption‚  automobile industry‚  energy efficiency


Target EU Legislation

  • Waste
  • Directive 2008/98 - Waste and repealing certain Directives (Waste Framework Directive) (19.11.200 ...
  • COM(2015)614 - "Closing the loop - An EU action plan for the Circular Economy" (02.12.2015)
  • Climate Change & Energy efficicency
  • Directive 2012/27 - Energy efficiency (25.10.2012)

Natura 2000 sites

Not applicable


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Beneficiaries:

Coordinator TFM Automotive & Industry S.p.A.
Type of organisation Large enterprise
Description TFM Automotive & Industry S.p.A. is a company producing mechanical and structural components for the automotive and motorbike industry. In the early 2000s, TFM widened the range of its technological products by developing a powder metallurgy (PM) division. Currently TFM, thanks to the combination of machining and powder metallurgy production, can be considered one of Europe’s leading automotive suppliers of high-performance mechanical components.
Partners Università degli Studi di Trento, Italy Sacmi Cooperativa Meccanici Imola S.C., Italy K4Sint S.r.l., Italy

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Project reference LIFE16 ENV/IT/000231
Duration 01-JUL-2017 to 31-DEC -2020
Total budget 3,251,673.00 €
EU contribution 1,908,703.00 €
Project location Trentino-Alto Adige(Italia) Veneto(Italia) Emilia-Romagna(Italia)

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Read more:

Leaflet "LIFE 4GreenSteel" (4.58 MB)

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Project description   Environmental issues   Beneficiaries   Administrative data   Read more   Print   PDF version