Coventry University and Alucast Advance Recycled Aluminium for High-Grade Manufacturing Applications

Coventry University is collaborating with UK aluminium foundry Alucast to explore how recycled aluminium can be processed into high-grade alloys suitable for industries such as automotive and defence. The project, delivered through the Clean Futures Programme, aims to increase the use of recycled feedstock while reducing the UK's reliance on imported primary aluminium.

The research focuses on identifying end-of-life aluminium streams that can be recovered and refined to meet the stringent quality requirements of critical manufacturing applications. According to the university, the UK imports up to 1.25 million tonnes of primary-grade aluminium each year because domestic production is insufficient to meet industrial demand.

Researchers from Coventry University’s Institute for Advanced Manufacturing and Engineering (AME) have analysed the lifecycle of aluminium products and post-consumer processing routes to identify higher-quality scrap sources that can be reprocessed into premium-grade alloys. The work is intended to help manufacturers secure alternative raw material supplies while reducing production costs and carbon emissions.

The initiative supports broader efforts to strengthen domestic supply chains by replacing a portion of imported primary aluminium with recycled material. Recycling aluminium also avoids the energy-intensive refining of aluminium ore, significantly lowering the embodied carbon associated with metal production.

Professor Marcos Kauffman, Director of Coventry University’s Institute for Advanced Manufacturing and Engineering, said the project demonstrates how applied research can deliver both commercial and environmental benefits.

“Our work together through the Clean Futures Programme is a great example of directed, actionable research for immediate impact for both commercial and sustainability benefit.”

He said developing pathways to use recycled aluminium in high-value manufacturing could help localize critical material supply, diversify feedstock sources and reduce emissions associated with primary aluminium production, while improving the competitiveness of UK manufacturers.

John Swift, Director of Alucast, said the collaboration has already produced encouraging technical results.

“With assistance from Coventry University, Alucast were able to source a different type of end-of-life aluminium scrap which after sorting and alloying up, we were able to achieve equivalent mechanical properties as primary grade aluminium in both test bars and automotive production castings.”

The partners said the project demonstrates the potential for carefully selected and processed recycled aluminium to meet the performance standards required for demanding industrial applications, supporting the development of more circular manufacturing supply chains in the UK.

Source: Coventry University

SUNSHINE Spotlight: The Coventry University–Alucast project highlights growing efforts to replace imported primary aluminium with high-quality recycled feedstock for advanced manufacturing applications while reducing supply chain emissions.