Recycled aluminium feedstock in metal additive manufacturing: A state of the art review
Vladislav Yakubov,
Halsey Ostergaard,
Shishira Bhagavath,
Chu Lun Alex Leung,
James Hughes,
Evren Yasa,
Mani Khezri,
Sandra K. Löschke,
Qing Li,
Anna M. Paradowska
Affiliations
Vladislav Yakubov
School of Civil Engineering, The University of Sydney, Sydney, NSW, Australia; Corresponding author
Halsey Ostergaard
School of Civil Engineering, The University of Sydney, Sydney, NSW, Australia; Australian Nuclear Science and Technology Organisation, Kirrawee, NSW, Australia
Shishira Bhagavath
Department of Mechanical Engineering, University College London, London, UK
Chu Lun Alex Leung
Department of Mechanical Engineering, University College London, London, UK; The Research Complex at Harwell, Harwell Campus, Oxfordshire, UK
James Hughes
University of Sheffield, Advanced Manufacturing Research Centre (AMRC), Sheffield, UK
Evren Yasa
University of Sheffield, Advanced Manufacturing Research Centre (AMRC), Sheffield, UK
Mani Khezri
School of Civil Engineering, The University of Sydney, Sydney, NSW, Australia
Sandra K. Löschke
Sydney School of Architecture, Design and Planning, The University of Sydney, Sydney, NSW, Australia
Qing Li
School of Aerospace, Mechanical and Mechatronic Engineering, The University of Sydney, Sydney, NSW, Australia
Anna M. Paradowska
School of Civil Engineering, The University of Sydney, Sydney, NSW, Australia; Australian Nuclear Science and Technology Organisation, Kirrawee, NSW, Australia; School of Aerospace, Mechanical and Mechatronic Engineering, The University of Sydney, Sydney, NSW, Australia; Corresponding authorSchool of Civil Engineering, The University of Sydney, Sydney, NSW, Australia.
Additive manufacturing has revolutionised the production of functional components and assemblies, offering a high degree of manufacturing flexibility. This review explores the latest advancements in additive manufacturing, focusing on its fusion-based and solid-state based technologies, and highlights the use of recycled aluminium as feedstock in these processes. The advantages and limitations of incorporating recycled materials are thoroughly analysed, considering factors such as material properties, sustainability, and process acceptance. While up to 14.4 kg CO2 per kg of aluminium is released during primary aluminium ingot production, solid-state based additive manufacturing, which is tolerant of feedstock contamination, can directly recycle aluminium. Meanwhile, fusion based additive manufacturing can readily utilise recycling pathways such as maintaining grade, upcycling, and downcycling, as well as powder reuse, providing opportunities for significant emissions reduction. The examination of feedstock manufacturing in this review, such as wire for WAAM and powder for PBF, indicates that this step indirectly increases the resource consumption of additive manufacturing. Finally, the alignment of aluminium recycling and additive manufacturing with Circular Economy principles and the UN's sustainable development goals are addressed, highlighting contributions to SDGs 3, 9, and 12.
