Aluminium's role as a key material in automotive and electric vehicle (EV) manufacturing is increasingly evident. In internal combustion engine (ICE) vehicles, aluminium is commonly used in engine blocks, transmission housings, wheels, suspension systems, body panels, interior trim, headlights, and taillights. In contrast, electric vehicles (EVs) rely heavily on aluminium for the battery pack, chassis, battery enclosures, and charging stations.

Image Source: Hydro

Aluminium's lightweight nature and high durability make it a preferred material for EVs, especially in structural components. It can withstand extreme forces, resist corrosion caused by saltwater and road salt and extend the lifespan of electric vehicles. But what many may not realize is the high recycling value of aluminium when vehicles reach the end of their life cycle.

Recycling Aluminium from End-of-Life Vehicles

According to the International Aluminium Institute, over 30 million tonnes of aluminium are recycled globally each year. While the rise of EV sales since 2017 is promising, it's still too early to see significant recycling volumes from these vehicles. However, preparing for this eventuality is crucial.

Vehicle parts are made from various aluminium alloys, each designed to meet specific performance requirements. For instance, steering rods must retain strength under high engine temperatures, while fenders need to absorb impact in collisions. If all the aluminium from a car is melted together, the resulting mix loses the properties of the individual alloys, rendering it less effective for future applications.

Piotr Chmielewski, Head of Automotive, Europe at Hydro Extrusions, comments, “By 2030, around 65% of cars produced will be electric, with the remaining 35% still using combustion engines. By 2035, all production will shift to electric vehicles, signaling the need for more specialized aluminium recyclers.”

As vehicle electrification progresses, the need for precise recycling processes becomes more critical.

Current Recycling Practices and Challenges

Currently, recycling of end-of-life vehicles (ELVs) involves mixing aluminium scrap with primary metal and downcycling it into cast engine blocks. However, the growing importance of aluminium for electric vehicles may change this approach. According to a study published on Science Direct, revising how aluminium alloys are classified could make it possible to recycle ELV scrap directly into high-quality wrought alloys, bypassing the need for cast engine blocks. This shift could lead to more efficient upcycling, producing alloys with properties suited to the growing demand for lightweight automotive components.

Why Segregation Matters in Recycling

James White, Recycling Product Manager at Eriez Magnetics Europe, discusses the rising challenges and opportunities in EV recycling:

“The increase in EVs will inevitably bring its own set of challenges. Battery recycling will be a necessity, as batteries last around 8-12 years in regular use. Recovery of precious metals like lithium, cobalt, and nickel is critical due to their limited availability globally,” says White.

He continues, “EV chassis and body panels contain significant amounts of aluminium, stainless steel, mild steel, and copper, all of which can be recycled if processed correctly. Manufacturers must collaborate with recyclers to improve separation and recycling techniques for end-of-life vehicles. Car recyclers are becoming more aware of how crucial good-quality pre-shred sorting and disassembly are in producing clean scrap. Reducing contaminants like copper and chrome is vital, and new separation technologies are being developed to improve the process.”

Key Challenges in Aluminium Recycling

There are three main challenges in recycling aluminium from vehicles:

1. Accurate Segregation: Efficiently separating all aluminium components and removing impurities from the metal.
2. Contaminant Identification: Identifying any remaining impurities and figuring out how to prevent them from complicating the recycling process.
3. Maximizing Scrap Value: Exploring every piece of scrap to develop high-quality alloys, which requires balancing quality with the inevitable impurities present in the recycled materials.

Conclusion: The Hidden Benefits of Aluminium in Vehicles

Aluminium is a premium choice for reducing vehicle weight compared to steel, improving fuel efficiency and extending the range of electric vehicles. Furthermore, aluminium’s 100% recyclability makes it an environmentally sustainable material for automakers aiming to reduce their environmental impact.

As the automotive industry shifts towards electric vehicles, the focus on recycling aluminium will only grow. Automakers should take note of this material’s full potential, both in terms of performance and its environmental benefits.