Advances in aluminum recycling that can help secure U.S. supply chains are the focus of a new five-year, $2.5 million research partnership between the University of Michigan and Norway-based company Hydro.
Hydro, one of the world's largest aluminum companies, opened a $150 million metal recycling plant in southwest Michigan in 2023 as part of a push to grow its U.S. manufacturing capabilities. The company also operates two R&D facilities in Michigan— one at the Cassopolis plant site that supports recycling operations, and a second in Troy focused on extruded products.
Extrusion is the process of pushing heated log-shaped aluminum billets through a die to form various shapes. Extruded products include crash-management components of automobiles, rails and floors for commercial transportation, and glass frames for building facades, for example.
This collaboration with the U-M College of Engineering establishes the Center for Recycling, Extrusion and Aluminum Technology, or the CREATe Partnership. It builds on an effort already underway, funded by the U.S. Department of Energy, to establish a Midwest circular economy in automotive aluminum.
"This partnership brings together top minds in materials science and manufacturing to expand what's possible in recycling aluminum, a metal that packs incredible strength into a lightweight form and has become one of the world's most widely used engineering materials," said Karen A. Thole, the Robert J. Vlasic Dean of Engineering at U-M. "Both Michigan Engineering and Hydro see tremendous potential in this research and this region to shape a more resilient future together."
The research partnership is Hydro's first with an American university.
“Hydro was founded 120 years ago at the intersection of a commercial visionary and a brilliant researcher. That spirit still defines us," said Eivind Kallevik, president and CEO of Hydro. "Industrial progress happens when industry and science work together to solve problems and develop new solutions. I look forward to following this collaboration between Hydro and the University of Michigan—and to seeing it drive new advances in aluminium recycling and alloy innovation."
Demand for aluminum has been increasing over the past decade as its utility in energy efficiency became apparent. Lightweight aluminum alloys contribute to better fuel economy in cars and trucks, and they're essential components of solar panels and power lines.
While aluminum is considered endlessly recyclable, each cycle introduces impurities—especially iron—that can weaken the metal and limit its use in high-performance applications. The collaboration aims to develop aluminum alloys that remain strong even after multiple life cycles. It includes three projects focused on how to address impurities.
One team will explore whether applying a low electric current to recycled aluminum while it's solidifying can reduce the effect of the iron impurities that degrade performance in generations beyond the first. This team is led by Alan Taub, the Robert H. Lurie Professor of Engineering in materials science and engineering and mechanical engineering. Taub is also director of the U-M Electric Vehicle Center.
Another group will take aim at iron impurities with a chemical, rather than electrical approach. Led by Ashwin Shahani, associate professor of materials science and engineering, this team will explore whether adding chemical elements to alloys can reduce the impact of impurities. Also involved in this effort are Katsuyo Thornton, the L.H. and F. E. Van Vlack Professor of Materials Science and Engineering; and Daniel Cooper, associate professor of mechanical engineering. Shahani is also involved in the project Taub leads.
A third team will use advanced computational tools and experiments to design alloys and processes that can tolerate higher percentages of recycled material. John Allison, the William F. Hosford Collegiate Professor of Materials Science and Engineering, leads this project, which uses tools he honed at Ford before joining U-M. Allison will also pilot a research-focused master's degree track to more closely connect the curriculum to industry needs.