Breakthrough published in “Nature Communications” – scientific community recognizes industrial relevance: How can the aluminum from an end-of-life vehicle be turned back into high-quality sheet metal for new vehicles—without labor-intensive sorting and without the addition of primary aluminum? Researchers at Montanuniversität Leoben have now found an answer. The results were published in the renowned journal “Nature Communications.”
Under the leadership of Univ.-Prof. Stefan Pogatscher, an industrially scalable process was developed that “upcycles” mixed aluminum scrap from end-of-life vehicles directly into high-quality, formable sheet metal without complex sorting or the addition of primary aluminum. The process was developed at the Chair of Non-Ferrous Metallurgy by a team led by doctoral student Patrick Krall.
While recycling a beverage can works so well because nearly identical alloys can be reprocessed into new cans, the situation is different for vehicles, as they consist of numerous different aluminum alloys. In current recycling processes, this results in complex mixtures that can usually only be used for downcycling. However, the new process developed at the Montanuniversität directly reuses this mixed stream. Supposedly harmful impurity elements are specifically incorporated metallurgically, eliminating the need for sorting, dilution, and downcycling steps. This opens up a directly applicable, circular pathway to high-quality secondary rolled alloys. The alloys produced in this process combine high strength with high ductility—that is, the ability to deform plastically without breaking—and are therefore also suitable for demanding applications.
Current challenges and future action required
This development comes at a critical juncture, as Europe generates seven to nine million tons of aluminum scrap from end-of-life vehicles each year. Currently, this material is primarily processed into cast alloys for internal combustion engines—with limited performance characteristics. However, the transition to electromobility is eliminating a key market. Without new applications, there is a risk of significant material surpluses and additional CO₂ emissions resulting from the replacement with primary aluminum. According to estimates, this could lead to additional emissions on the order of approximately 90 million tons of CO₂ per year by 2030.
The process developed at the Montanuniversität opens up an immediately applicable, circular pathway to high-quality secondary rolled alloys, thereby enabling a paradigm shift in alloy development.
Instead of eliminating impurity-rich intermetallic phases through sorting or dilution, they are specifically adjusted and distributed. These particles refine the microstructure and enhance mechanical properties. A heterogeneous scrap mixture is thus transformed into a high-performance, formable rolled alloy—without the addition of primary aluminum.
International Recognition and Funding
In addition to its publication in “Nature Communications,” the approach was also highlighted in a Research Highlight by “Nature Reviews Materials” and classified as highly relevant to industry. Shortly after the publication of a preprint, the British popular science magazine *New Scientist* also reported on the research findings.
The project was funded under the ERC Consolidator Grant HETEROCIRCAL. At its core is the fundamental question of how the increasing complexity of materials and alloys in modern products can be reconciled with a circular economy.
Next Steps Toward Industrial Application
Further work will now focus on expanding the material’s performance profile to open up additional fields of application. At the same time, efforts are underway in collaboration with industry partners to scale up the technology. Several companies have already expressed interest, and major European implementation projects are being prepared.
This could mark a milestone for a circular aluminum economy in Europe.
[Source: Montanuniversität Leoben, March 16, 2026]