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From waste to recyclable material: scrap metal as the key to new structures in automotive engineering
The automotive industry worldwide is faced with the task of meeting growing demands for sustainability, resource efficiency and climate protection. Aluminium plays a central role in this: it is light, stable and enables energy-efficient mobility. However, the primary production of the metal is associated with enormous energy consumption and significant CO₂ emissions. Recycled aluminium could make a decisive contribution here, but the fluctuating quality of scrap alloys has so far made it difficult to use them on a large scale in demanding applications such as structural and safety components. This is exactly where the European research project Digi4Circular comes in. Also on board is the LKR Leichtmetallkompetenzzentrum Ranshofen of the AIT Austrian Institute of Technology, which is contributing its comprehensive expertise in alloy development and casting technology to
Problem: Quality fluctuations slow down recycling
Although recycled aluminium offers enormous ecological advantages, there are still challenges associated with its industrial use. Different compositions of scrap metal lead to varying mechanical properties, which can prevent its processing or use in highly stressed components. Previous solutions have often been based on energy- and cost-intensive processes such as upcycling or downcycling, which means that a significant part of the sustainability potential is lost. In order to achieve the transformation to a truly circular economy, materials, processes and product development must therefore be more closely interlinked.
Digi4Circular: Digitalisation as a lever for the circular economy
Funded by Horizon Europe, Digi4Circular pursues a consistently digital approach. With the help of simulation platforms such as Synera, the entire process chain – from the selection of recycled material to alloy development and component design – is to be supported on a data-based basis.
This means that components are designed for recyclability at an early stage of development without compromising on quality or safety. Depending on the available scrap composition, suitable alloys can be identified and optimally utilised without the need for costly upcycling or downcycling. This approach is complemented by rapid life cycle and cost analyses that directly highlight the ecological and economic impacts. Another central element of the project is the introduction of digital product passports, which document material flows along the entire value chain, thus ensuring transparency and traceability.
Contribution of LKR: Materials expertise for industrial applications
The LKR Leichtmetallkompetenzzentrum Ranshofen of the AIT Austrian Institute of Technology is one of ten partners in the European consortium and contributes its many years of experience in alloy development and casting technology to the project.
The focus is on developing new aluminium alloys with a higher recycled content and investigating the microstructural effects that occur when scrap material is used. The main objective is to control phase formation and intermetallic networks in such a way that ductility, strength and workability are optimised and process reliability is improved. LKR is thus playing a key role in translating the principles of the circular economy into practical material solutions and ensuring their application in the automotive industry.
Dr. Katrin Mester, project manager at LKR, emphasises the relevance of the project: "With Digi4Circular, we are laying the foundation for scrap to no longer be considered waste, but rather a valuable resource for new vehicle components. Digital tools make it possible to select the right alloy depending on the scrap composition and, if necessary, even to adapt the component design with the aid of simulations. This allows us to use recycled aluminium even in safety-critical applications, thereby making a decisive contribution to the transformation towards a truly circular economy."
Consortium and funding
Digi4Circular was launched in Paderborn in December 2024 and will run for three and a half years. Ten partners from six European countries are working together on its implementation, including research institutions and industrial companies: Paderborn University (coordination), EDAG Engineering GmbH, the LKR Leichtmetallkompetenzzentrum Ranshofen of the AIT Austrian Institute of Technology, University of Florence, Data CoLAB, SusDAT, EIT Manufacturing, Fraunhofer LBF, Celsa, Ferimet and AMIRES.
The project is funded by the European Union's Horizon Europe research and innovation programme (Grant Agreement No. 101177586). A total of €5.76 million is available for this purpose.
Further information: www.digi4circular.eu