A review on solid-state recycling of aluminum machining chips and their morphology effect on recycled part quality
Open accessAbstract
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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- 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)
- PMC
- PMC11325671
- 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
- gold
- doi.org
- Licence
- 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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