Aluminum and innovation: the future of alloy production in Rovereto

Aluminum and its alloys have become a cornerstone of modern engineering, owing to their distinctive properties and the growing demand spurred by the global energy transition. Unlike ferrous alloys, aluminum is a relatively modern material, produced using electricity, with an anticipated annual growth rate of 2% in the coming years.

The production of aluminum billets is predominantly driven by the aerospace, automotive, and transportation sectors, all of which demand high-performance materials. In this landscape, aluminum extrusion remains one of the most essential processes employed. A market that continuously demands better performance pushes manufacturers to innovate relentlessly in pursuit of improved production efficiency.

A notable example of a company rising to this challenge is Almec Tech Srl, based in Rovereto. For over 70 years, this family-run business has been producing and distributing aluminum casting equipment on a global scale, competing with international giants. Its strategy to remain competitive hinges on constant innovation, serving as a metaphorical “slingshot” against the “Goliaths” of the global market.

Almec Tech has chosen to evolve its legacy by embracing cutting-edge research, finding an ideal partner in the Department of Industrial Engineering (DII) at the University of Trento. This collaboration culminated in the 2023 launch of a doctoral research project titled “Study of the shell zone segregation in hard Al alloys ingots produced by semicontinuous casting process.” This ambitious initiative involves Almec Tech Srl, doctoral candidate Alessio Malandruccolo, and metallurgy professor Cinzia Menapace.

The project focuses on innovating the direct-chill casting (DCC) process used in aluminum alloy billet production. The goal is to design a hot-top mold that minimizes the thickness of the initial solidified layer of material, known as the shell zone, meeting the extrusion industry’s demand for ultra-thin layers measured in microns. Furthermore, the research aims to model the casting process to predict the shell zone thickness based on alloy composition, billet diameter, and other process parameters.

Significant progress has already been made, starting with an extensive literature review followed by experiments to validate the gathered data. The early results are promising, enabling Alessio Malandruccolo to present his findings at the 40th National AIM Conference in Naples in September 2024. Additionally, the project was showcased at Aluminium 2024 in Düsseldorf, Europe’s premier event for the sector, where Alessio presented the research advancements alongside Almec Tech Srl.

This project exemplifies how collaboration between businesses and universities can drive innovation, enabling small and medium-sized enterprises to tackle the challenges of an increasingly competitive global market. Through this synergy, Almec Tech Srl continues its journey of innovation, aiming to maintain its edge in the aluminum alloy equipment sector by investing in advanced technological solutions and research-driven development.