Die casting is a cutting-edge manufacturing process which is increasingly used to make aluminum components from automobile powertrain and body structures to intricate computers and medical devices. However, the high energy consumption and considerable CO2 emissions in primary aluminum production can compromise the environmental and economic benefits of lightweight aluminum applications.

In this project webinar, we learn about how commercially available options and processes in development for sortation of automobile steel scrap were evaluated to determine if there may be a viable method to remove some of the undesirable impurities prior to feeding to an electric arc furnace.

Non-destructive evaluation (NDE) of fatigue damage in recycled materials is essential to maximize the benefits of utilizing such materials for remanufacturing. We will present an innovative NDE technology that smartly combines the strengths of multiple NDE methods (e.g., acoustic emission, infrared imaging, linear ultrasound, and nonlinear ultrasound) using machine learning. This technology is expected to achieve a 10–15% improvement in the prediction accuracy of remaining useful life compared to existing methods.

Secondary aluminum is playing an increasing role in the global economy, particularly in countries with long histories of aluminum usage. In fact, since 2001, secondary aluminum production in the United States surpassed primary aluminum production with many positive benefits such as lower cost, energy savings, and environmental stewardship. However, limited quantities of secondary aluminum alloys are presently used in the die casting industry because of the higher concentrations of residual contaminants such as iron and zinc in the secondary materials compared with primary aluminum.

This webinar will provide an overview of the current secondary aluminum and die casting industries. Additionally, the seminar will present the latest progress on two REMADE-funded research projects.

Electrodynamic sorting (EDX) is a new form of eddy current separation developed at the University of Utah. Rather than rotate a cylindrical drum of permanent magnets, this technology excites a stationary electromagnet with an alternating electrical current. The resulting frequency of excitation is far greater than anything which can be achieved through mechanical rotation, allowing the separation of nonferrous metals from other nonferrous metals.

In its present embodiment, the assembly is capable of processing over 1 ton of industrial Zorba per hour. After passing through the magnetic field, lightweight aluminum particles are thrown up and over a mechanical divider, resulting in an enriched 97 % aluminum product. Recovery of the aluminum is also very high, with typical values ranging between 80—90 %.

During this one hour webinar, Dr. Michael Free will provide an overview of metals recycling. He will discuss the sources of metal scrap and the processes by which metals are separated and recycled into purified metals. Dr. Free will cover specific details for steel, aluminum, copper, and precious metals recycling, and he will discuss the opportunities for future recycling and the inherent economic and environmental values in metals recycling.

Michael Free is a Professor of Metallurgical Engineering at the University of Utah in Salt Lake City, Utah. His areas of expertise include corrosion, electrometallurgy, hydrometallurgy, and materials synthesis.

Recycling markets around the world are experiencing significant upheaval.
In this webinar, join internationally recognized sustainability expert David Refkin—Resource Recycling Systems' senior affiliate consultant, REMADE Institute's Strategic Advisory Committee chair and Governance Committee member, and Dr. Michael Free—technical leader for the recycling & recovery arm of the REMADE Institute and a professor for the Department of Metallurgical Engineering at the University of Utah.

David and Michael will explore the challenges and opportunities that exist in the current global recycling landscape and discuss the vast, cross-industry implications.

In this webinar, you'll learn more about:

• How international policies impact recycling around the world

• Why the domestic recycling industry is concerned about the implications

• What opportunities exist to improve outcomes and will technology play a big role?