Recycling aluminium for sustainable development: A review of different processing technologies in green manufacturing

• Published in: Results in engineering Vol. 23; p. 102566
• Main Authors: Al-Alimi, Sami, Yusuf, Nur Kamilah, Ghaleb, Atef M., Lajis, Mohd Amri, Shamsudin, Shazarel, Zhou, Wenbin, Altharan, Yahya M., Abdulwahab, Hamza Salah, Saif, Yazid, Didane, Djamal Hissein, S T T, Ikhwan, Adam, Anbia
• Format: Journal Article
• Language: English
• Published: Elsevier B.V 01.09.2024; Elsevier
• Subjects: Direct metal recycling; Hot extrusion; Hot forging; Life cycle assessment; Powder metallurgy; Life cycle assessment; Hot extrusion; Direct metal recycling; Powder metallurgy; Hot forging
• ISSN: 2590-1230; 2590-1230
• DOI: 10.1016/j.rineng.2024.102566

Climate change is a significant global environmental issue that has attracted extensive research and debate. Consequently, the concept of sustainability in the context of aluminium encompasses multiple dimensions. Within the discussions surrounding waste and resource management, there is ongoing deliberation about the actual environmental advantages offered by material recycling. The high demand for raw materials has prompted researchers to explore sustainable recycling processes, with a particular focus on processing technologies. A comprehensive examination of these diverse methods is crucial for understanding three main techniques for aluminium forming: conventional recycling (CR), semi-direct recycling (SDR), and direct recycling (DR). Through a systematic review, it becomes evident that SDR and DR, which incorporate a forming process, present substantial environmental, energy, and cost benefits while promoting sustainability awareness in the manufacturing sectors. This extensive review also encompasses nine life cycle analysis (LCA) studies, comprising sixteen scenarios that have employed various methodologies to assess the environmental impact of managing waste aluminium through different approaches: recycling (melting and solid-state), incineration, or landfill. The outcomes of this comprehensive international review provide a more unbiased evaluation of the environmental effects associated with various wastes management systems. The majority of the studies indicate that recycling offers superior environmental solutions and fewer environmental effects compared to alternative waste green forming management options. •Plastic deformation manufacturing methods in the context of aluminium solid-state recycling are novel approaches to transforming and repurposing aluminium materials that do not rely on the standard melting procedure. The fundamental goal of these strategies is to establish a more sustainable and environmentally friendly way to handle light metal aluminium. The fundamental goal of these strategies is to produce a more sustainable and eco-friendly way to managing light metal aluminium.•Aluminium is a lightweight and adaptable metal that is widely utilized in a variety of sectors, including aerospace and automotive, as well as building and packaging. The standard recycling method for aluminium, on the other hand, often includes melting the material, which needs a significant amount of energy. Furthermore, this procedure may result in some material property loss and may not be the most effective approach to recycle aluminium, especially when working with scrap or end-of-life items.•Plastic deformation manufacturing processes, on the other hand, use techniques like cold or heated forging, extrusion to form aluminium without melting it. This preserves the structural integrity and characteristics of the aluminium, resulting in a higher-quality recycled material.•These technologies are especially well-suited for recovering aluminium items that have previously been heavily processed and have unique forms and architectures. For example, utilizing plastic deformation processes, outdated aluminium vehicle parts, aviation components, or building materials may be successfully recycled. By doing so, it not only saves energy but also minimizes the environmental effect of producing new aluminium from raw materials.•The proposed manufacturing technologies provide a sustainable and ecologically friendly alternative to aluminium recycling They allow for the reuse of aluminium materials without the requirement for energy-intensive melting while keeping the material's desired qualities. These technologies are critical in establishing a circular economy and lowering the carbon footprint connected with aluminium production, making them a significant tool in the pursuit of more sustainable manufacturing processes.