Study examines aluminium vs iron energy balance

The conclusions of a Cranfield University project into the life cycle energy analysis of aluminium versus cast iron, and its implications for the automotive industry, will be published before the year end of 2016.

The findings of the study will be published by Dr Mark Jolly, Professor of Sustainable Manufacturing at Cranfield University.

As a precursor to the conclusions, Professor Jolly introduced prior studies at the annual general meeting this week of SinterCast in Stockholm.

These studies showed the energy intensity and CO2 emissions of aluminium production relative to cast iron, and emphasised the importance of life cycle energy analysis, particularly in the automotive industry.

In particular, Professor Jolly noted that the production of 1kg of primary aluminium generates approximately 10kg of CO2 – four times that of iron.

Professor Jolly presented the outline of a new project that is being conducted at Cranfield University to quantify the energy consumption in each step of the cast iron and aluminium manufacturing processes, from mining through to manufacturing, on-road use and recycling.

The Cranfield study focusses on the entire manufacturing cycle of an engine cylinder blocks as this the single heaviest component in most passenger vehicles.

Professor Jolly plans to present the conclusions of the Cranfield University project before the end of 2016, as an input to decision makers in the automotive industry and to legislators, to promote holistic solutions that can improve the environment.
The outcome of the investigation, by a team of multi-national post-graduate engineers, could be vital in pointing up the supremecy of compacted graphite iron (CGI) as a lean-eneregy life cycle manufactured material for passenger and commercial vehicle applictions.