Cited by 45Metallurgy and Material FormingAdvanced Welding Techniques AnalysisAluminum Alloy Microstructure Properties

A review on solid-state recycling of aluminum machining chips and their morphology effect on recycled part quality

Open access
Altharan, Yahya M., Shamsudin, S., Al-Alimi, Sami, Saif, Yazid, Zhou, Wenbin·2024·Heliyon

Abstract

The increasing demand for sustainable manufacturing has revived the interest in solid-state recycling (SSR) as a promising alternative method for aluminum waste. In this context, chips generated during machining processes constitute a substantial portion of aluminum waste, offering significant potential for recycling and mitigating waste. However, the machining chip morphology significantly impacts the properties of chip-based recycled parts. This review paper examines the current state-of-the-art solid-state recycling methods, focusing on hot forging, extrusion, equal channel angular pressing, friction stir extrusion and field-assisted sintering. It investigates the impact of aluminum chip morphology on the properties of the directly recycled material, emphasizing the chip machining consequence on the final quality of the product. Several studies reported that the strain and operating temperature are the most influential factors in SSR processes, followed by chip size with an average length of less than 4 mm. Yet, the heating time up to 3 h also had a major impact on chip weld strength. The findings highlighted the significance of aluminum chip morphology in improving the quality of recycled material. The properties of direct recycled samples primarily depend on chip weld strength and microstructure. Overall, this study presented a comprehensive overview of the current state of solid-state recycling and emphasized the significance of chip morphology in advancing the recycling process. Consequently, it equips researchers with a valuable resource for developing effective strategies for sustainable recycling of aluminum chips with high quality.

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  • The life cycle environmental footprint of secondary aluminum depends on end-of-life recycling efficiency and regional electricity mix.

    “Although aluminum is infinitely recyclable, the life cycle environmental footprint of secondary aluminum depends on end-of-life recycling efficiency and regional electricity mix (7,8).”

    From Environmental life cycle assessment of single-use and reusable food takeaway containers (2025) · cites this paper as [8]

    The Introduction (page not provided) says aluminum is 100% recyclable and links losses during remelting to greater energy use and environmental impact. This supports the recycling-efficiency part of the claim, but the passages found do not address regional electricity mix as a determinant of the life-cycle footprint. (LLM, conf=0.85)

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9 of the 145 references couldn’t be matched to a known paper.

Research works printed but not linked: 14

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Authors
Altharan, Y. M., Shamsudin, S., Al-Alimi, S., Saif, Y., & Zhou, W.
Affiliations
  • Tun Hussein Onn University of Malaysia (MY)
  • University of Dundee (GB)
Corresponding author
  • Altharan, Yahya M.
  • Shamsudin, S.
  • Zhou, Wenbin
Venue
Heliyon
Publisher
Elsevier BV
Published
2024-07
Volume
10
Issue
14
Pages
e34433
ISSN
2405-8440 (ISSN-L)
OpenAlex
W4400623913
Cited by
42
References
145
Citations by year
2026: 25 · 2025: 13 · 2024: 4
FWCI
2.04
Type
journal article
Language
en
Open access
Locations
  • Heliyon (publishedVersion, cc-by-nc-nd)
  • PubMed Central (publishedVersion, cc-by-nc-nd)
  • PubMed (publishedVersion)
  • Discovery Research Portal (University of Dundee) (submittedVersion, cc-by-nc-nd)
  • DOAJ (DOAJ: Directory of Open Access Journals) (submittedVersion)
Funders
  • Universiti Tun Hussein Onn Malaysia (Q390, E15216)
  • University of Dundee
Topics
  • Physical Sciences › Engineering › Mechanics of Materials › Metallurgy and Material Forming
  • Physical Sciences › Engineering › Mechanical Engineering › Advanced Welding Techniques Analysis
  • Physical Sciences › Engineering › Aerospace Engineering › Aluminum Alloy Microstructure Properties
Keywords
solid-state recycling, chip morphology, hot forging, extrusion, equal channel angular pressing, friction stir extrusion, field-assisted sintering, microstructure, sustainable manufacturing

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