Scientists reinvent the aluminum wheel with 30 percent recycled metal

Researchers at Dortmund University of Applied Sciences and Arts in Germany have developed an innovative aluminum wheel alloy incorporating 30 percent recycled metal, aiming to reduce the carbon footprint of automotive wheels without sacrificing performance or design. The SUPA-Wheel project addresses the high energy consumption and CO2 emissions associated with producing new aluminum, which emits roughly 15 tons of CO2 per ton due to energy-intensive extraction and electrolysis processes. In contrast, recycled aluminum requires only about 5 percent of that energy, but its variable composition has historically made it challenging to maintain the precise alloy properties needed for wheel strength, hardness, and corrosion resistance. To overcome these challenges, the research team collaborated with industry partners including wheel manufacturer Borbet, Fraunhofer IGCV, aluminum producer Trimet Aluminium, and plastics specialist Jordan Spritzgusstechnik. They tested around 300 alloy samples and developed a predictive model to fine-tune the alloy composition, ensuring stability despite the inclusion of recycled material. While current supply constraints limit recycled aluminum content