Evaluation of solid-state recycling processes for aluminum chips by microstructure-based performance and screening-level life cycle assessment

Aluminum plays an important role in lightweight design and circular material strategies due to its favorable mechanical properties and recyclability. However, its conventional processing routes, particularly those involving remelting, remain highly energy- and emission-intensive, which poses a significant challenge for sustainable manufacturing. Solid-state recycling (SSR) offers a promising route for recycling aluminum chips directly into components without the need for melting, thereby reducing energy consumption and emissions associated with traditional methods. This study evaluates the performance and environmental impact of SSR methods using microstructure-based metrics and a screening-level life cycle assessment (LCA). The methodology includes an analysis of the mechanical properties of the recycled materials and the environmental benefits of reduced energy usage. Results indicate that SSR processes significantly improve the sustainability of aluminum recycling by lowering the carbon footprint and enhancing material properties, which is crucial for achieving a more sustainable production framework. The findings demonstrate that adopting SSR techniques can contribute to the development of a circular economy for aluminum, minimizing waste and maximizing resource efficiency.