Recycled aluminium feedstock in metal additive manufacturing: A state of the art review

Recycled aluminium feedstock in metal additive manufacturing: A state of the art review

2024 | Vladislav Yakubov, Halsey Ostergaard, Shishira Bhagavath, Chu Lun, Alex Leung, James Hughes, Evren Yasa, Mani Khezri, Sandra K. Löschke, Qing Li, Anna M. Paradowska
This review explores the integration of recycled aluminum as feedstock in additive manufacturing (AM), focusing on both fusion-based and solid-state AM technologies. The advantages and limitations of using recycled materials are analyzed, considering factors such as material properties, sustainability, and process acceptance. Fusion-based AM, which is sensitive to feedstock contamination, can directly recycle aluminum, while solid-state AM processes, such as additive friction stir deposition (AFSD) and friction stir welding (FSW), can tolerate feedstock contamination and offer opportunities for significant emissions reduction through recycling pathways like maintaining grade, upcycling, and downcycling. The review also examines the environmental impact of feedstock manufacturing, such as wire for wire-arc additive manufacturing (WAAM) and powder for powder-bed fusion (PBF), and discusses the alignment of aluminum recycling with Circular Economy principles and the UN's Sustainable Development Goals (SDGs). The study highlights the potential of AM to reduce energy use, material waste, and maintenance costs, while also addressing the challenges of recycling and reuse of metallic materials to enhance sustainability.This review explores the integration of recycled aluminum as feedstock in additive manufacturing (AM), focusing on both fusion-based and solid-state AM technologies. The advantages and limitations of using recycled materials are analyzed, considering factors such as material properties, sustainability, and process acceptance. Fusion-based AM, which is sensitive to feedstock contamination, can directly recycle aluminum, while solid-state AM processes, such as additive friction stir deposition (AFSD) and friction stir welding (FSW), can tolerate feedstock contamination and offer opportunities for significant emissions reduction through recycling pathways like maintaining grade, upcycling, and downcycling. The review also examines the environmental impact of feedstock manufacturing, such as wire for wire-arc additive manufacturing (WAAM) and powder for powder-bed fusion (PBF), and discusses the alignment of aluminum recycling with Circular Economy principles and the UN's Sustainable Development Goals (SDGs). The study highlights the potential of AM to reduce energy use, material waste, and maintenance costs, while also addressing the challenges of recycling and reuse of metallic materials to enhance sustainability.
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[slides and audio] Recycled aluminium feedstock in metal additive manufacturing%3A A state of the art review