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U-M to partner with Hydro, one of the globe’s largest aluminum manufacturers.
Innovations in aluminum recycling aimed at strengthening U.S. supply chains constitute a new five-year, $2.5 million research alliance between the University of Michigan and Norway-based firm Hydro.
Hydro, among the largest aluminum corporations worldwide, inaugurated a $150 million metal recycling facility in southwest Michigan in 2023, as part of its initiative to enhance U.S. manufacturing capabilities. The corporation also runs two research and development facilities in Michigan—one located at the Cassopolis plant site supporting recycling activities, and another in Troy focusing on extruded products.
Extrusion refers to the method of forcing heated, log-shaped aluminum billets through a die to create various configurations. Extruded products encompass collision-management components for vehicles, rails and floors for commercial transport, and frames for glass facades, among others.
This partnership with the U-M College of Engineering establishes the Center for Recycling, Extrusion, and Aluminum Technology, also known as the CREATe Partnership. It builds upon an ongoing initiative funded by the U.S. Department of Energy to create a Midwest circular economy in automotive aluminum.
“This collaboration unites premier experts in materials science and manufacturing to broaden the potential of aluminum recycling, a metal that offers remarkable strength in a lightweight form and has emerged as one of the most utilized engineering materials globally,” stated Karen A. Thole, the Robert J. Vlasic Dean of Engineering at U-M. “Both Michigan Engineering and Hydro recognize significant promise in this research and this region to jointly build a more resilient future.”
The research collaboration marks Hydro’s inaugural partnership with a U.S. university.
“Founded 120 years ago at the confluence of a commercial visionary and an exceptional researcher, that spirit continues to define us,” commented Eivind Kallevik, president and CEO of Hydro. “Advancements in industry occur when commerce and science synergize to tackle challenges and create innovative solutions. I am eager to observe this collaboration unfold between Hydro and the University of Michigan—and anticipate it will catalyze new innovations in aluminum recycling and alloy development.”
Over the past decade, demand for aluminum has surged as its role in energy efficiency has become evident. Lightweight aluminum alloys enhance fuel economy in vehicles and serve as vital components in solar panels and power transmission lines.
Despite aluminum being regarded as perpetually recyclable, each cycle introduces contaminants—particularly iron—that can compromise the metal’s integrity and restrict its applicability in high-performance scenarios. This collaboration seeks to formulate aluminum alloys that maintain strength across multiple life cycles, encompassing three initiatives aimed at managing impurities.
One team will investigate the impact of applying a low electric current to recycled aluminum during its solidification to mitigate the effects of the iron impurities that diminish performance in subsequent generations. This effort will be led by Alan Taub, the Robert H. Lurie Professor of Engineering in materials science and engineering as well as mechanical engineering. Taub also directs the U-M Electric Vehicle Center.
A different team will target iron contaminants using a chemical method rather than electrical. This effort, led by Ashwin Shahani, associate professor of materials science and engineering, will explore whether incorporating chemical elements into alloys can minimize the repercussions of impurities. Katsuyo Thornton, the L.H. and F. E. Van Vlack Professor of Materials Science and Engineering, and Daniel Cooper, associate professor of mechanical engineering, are also collaborating on this project. Shahani is additionally involved in the initiative led by Taub.
A third team will leverage advanced computational methods and experimental techniques to engineer alloys and processes capable of accommodating greater proportions of recycled content. John Allison, the William F. Hosford Collegiate Professor of Materials Science and Engineering, leads this project, utilizing tools he perfected at Ford prior to his appointment at U-M. Allison will also launch a research-centered master’s degree pathway to better align the curriculum with industry demands.
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