Enabling a Low-Carbon Future with Recyclable Light Metal Alloys: From Efficient Production to Circular Light Metal Systems

Enabling a Low-Carbon Future with Recyclable Light Metal Alloys From efficient production to circular light metal systems Stefan Gneiger, Light Metal Technologies Ranshofen 09.12.2025 AIT –Austrian Institute of Technology LKR Ranshofen 2 •The AIT •is the largest non-university research organization of Austria, operating multiple research facilities throughout the country. •aims to bridge the gap between research and technology commercialization. •uses applied research to transfer emerging technologies into specific applications - up to demonstrators and prototyping. 09.12.2025 3 LKR - Light Metals Technologies Ranshofen •Subsidiary of the Austrian Institute of Technology (AIT) •Located in Ranshofen, Austria •70 employees •R&D for Al, Mg and Ti applications •Optimization & development of alloys / processes •Casting, forming and additive manufacturing facilities on semiindustrial scale •Simulation, KI analysis •Testing laboratory 09.12.2025 •CO2 emissions continue to rise globally despite efficiency gains •Transport = ~ 20 % of global total greenhouse gas emissions Starting Point: Global CO2 Emissions Global CO2emissions from energy combustion and industrial processes and their annual change, 1900-2023, [IEA25] Annual global energy consumption, [GBP21] Gt CO2 1900 1920 1940 1960 1980 2000 2024 0 10 20 30 40 First Oil crisis Second Oil crisis Gobal financial crisis COVID-19 pandemic 2020 Global Greenhouse Gas Emissions 5 09.12.2025 Global CO2 Emissions by Economic Sector Global CO2 Emissions by the Tranport Sector [IEA14] Light metals are key enablers for decarbonization •Aluminium and magnesium reduce energy consumption through lightweight design •Lower vehicle and aircraft mass → less fuel, lower CO₂ emissions •Essential for e-mobility, aerospace, and renewable energy systems •Offer design flexibility, system integration, and efficient mass production The Role of Light Metals in a Low-Carbon Future 6 09.12.2025 •Most widely used light metal in transport and construction •High strength-to-weight ratio, corrosion resistance and recyclability •Enables lightweight structures in various sectors •High energy demand in primary production Aluminium – Cornerstone of Modern Lightweight Structures 7 Global distribution of market shares for aluminium products [FMI25] Global Al use by sector [FMI25] Wrought 58% Cast 42% 09.12.2025 Transport 47% Building & Construction 13% Packaging 13% Engineering 12% Electrical 9% Others 6% Magnesium – A Key Enabler for Future Mobility 8 Mg use by sector, based on [Die18] and [Cla22] Aluminium alloys 34% Die castings 33% Titanium refining 11% Steel desulphurization 11% Nodular cast iron 6% Other 5% 09.12.2025 •Lightest structural metal (33 % lighter than aluminium) •Excellent specific strength and high damping capacity •High potential for CO2 reduction if barriers are overcome •Challenges: Corrosion, flammability, cost, and limited recycling loop •High-volume, high-precision production methods for aerospace, automotive and electronics •Enable thin-walled, complex, and net-shape components •High productivity, automation potential and excellent circularity potential • Increasing demand for secondary alloys → need for recycling tolerant compositions Challenges: Efficiency gains and maintaining performance with recycled alloys Al and Mg in Die Casting and Thixomolding 9 09.12.2025 Global Al Flows 2030 16 [Eyn22] 09.12.2025 European Mg Flows 2012 17 09.12.2025 [Oak17] Recycling rate of approximately 32% •Aluminium and magnesium are key enablers for low-carbon mobility and energy systems •Die-casting and Thixomolding provide efficient and scalable manufacturing routes •Circular economy is essential to move from linear to sustainable value chains •Recycling saves up to 95% of the energy compared to primary production Challenges •Downcycling limits the reuse of secondary light metals •Maintaining performance with recycled alloys Solution •Design alloys which can tolerate real-world impurity levels Intermediate Summary 18 09.12.2025 Projects Project „RecAL“ Recycling Technologies for Circular Aluminium 20 Funded by the European Union. Views and opinions expressed are however those of the author(s) only and do not necessarily reflect those of the European Union or HADEA. Neither the European Union nor the granting authority can be held responsible for them. Project 4 years 19 partners 10.9 M€ funding Develop a digital circularity platform (HUB) for the entire aluminium recycling value chain Optimize scrap purity by advanced sorting and refining technologies Provide data for CO2footprint and product passport Maximizing the impurity tolerance of nextgeneration alloys Goals Project Overview Funded by the European Union. Views and opinions expressed are however those of the author(s) only and do not necessarily reflect those of the European Union or HADEA. Neither the European Union nor the granting authority can be held responsible for them. The HUB is a digital cockpit tracking Alrecyclates across the continent, connecting suppliers with buyers. RecAL HUB Project „Digi4Circular“ Digital platform for data-driven and physics-based product development enabling a circular economy 23 Project Overview Goal: Development of comprehensive digital platform to enable circular product development with focus on the automotive industry Key Features: Automated Workflows, Machine Learning Algorithms, Life Cycle Data Integration, Environmental Impact Assessments, Digital Product Passport Project Information: 11 partners, 6 countries, 5.76 M€ Project „SUSTAINair“ SUSTAINability increase of lightweight, multifunctional and intelligent airframe and engine parts 25 THANK YOU! Stefan Gneiger, 09.12.2025