What is circular material design?
Circular material design refers to the development and evaluation of materials with the goal of closing material loops for as long as possible while maintaining high quality. The focus is not only on a material’s performance during use, but also on its recyclability, reusability, and processability within sustainable process chains. Materials are thus no longer considered exclusively for a single application, but rather throughout their entire life cycle—from manufacturing through use to their incorporation into new products.
The focus is on the interplay between chemical composition, microstructure, processing, and subsequent recycling. Particularly with metallic materials, the question arises as to how secondary raw materials and increased levels of residual or trace elements can be utilized without compromising the required properties. At the Chair of Materials Science and Testing, we investigate how composition and process control can be specifically adapted to produce high-performance materials even from recycled or more heavily contaminated feedstocks. The goal is to combine material quality, resource efficiency, and industrial applicability.
Research at the Department
Understanding Material Cycles, Harnessing Recycling Potential, and Developing Sustainable Process Chains
At the Chair of Materials Science and Testing, we view circular materials design as the interplay of material composition, process control, microstructure, and subsequent recycling. The central question is how secondary raw materials and increased levels of residual or trace elements can be utilized without compromising the required properties of engineering materials.
To this end, we combine materials science analysis, thermal and mechanical processing steps, and modern characterization methods. This allows us to systematically investigate the relationships between alloy composition, heat treatment, forming, microstructural development, and component properties. A particular focus is on the development of robust process chains that enable the production of high-quality materials from recycled feedstocks, thereby contributing to resource efficiency, the circular economy, and sustainable industrial production.
Methods and Skills
From Materials Analysis to the Process Chain
Analysis and optimization of manufacturing, heat treatment, forming, and finishing processes for resource-efficient material and component cycles.
Use of calculations, material data, and digital methods to evaluate phase formation and property development throughout the process chain.
An assessment of how materials and components can be used for longer, reused, or repurposed for new applications through appropriate processes.
Evaluation of primary and secondary materials, residual materials, and accompanying elements, as well as their influence on processability, microstructure, and material properties.
Investigation of microstructure, precipitates, and phase distributions to understand the influence of composition and process parameters on material behavior.
Testing of hardness, strength, deformation behavior, and damage mechanisms to evaluate the performance of circularly developed materials.
Projects in this subject area
Overview of Research Projects in the Field of Circular Materials Design
The ASAAP project investigates adaptive process chains for a more sustainable aluminum circular economy. The focus is on how aluminum materials with a higher recycled content can be processed in a way that continues to ensure high-quality component properties. At the LMW, particular emphasis is placed on the materials science evaluation of the process steps, microstructural development, and homogenization of recycled aluminum alloys.
ProSa focuses on how sustainability aspects can be systematically incorporated into product development from the outset. To this end, digital product signatures are being developed that consolidate technical and sustainability-related information throughout a product’s life cycle. The LMW contributes its expertise in materials evaluation, materials testing, and circular materials development to this effort.
TwinCE develops digital approaches for mapping and evaluating material cycles for non-ferrous metals. The goal is to link information on materials, processes, and supply chains in such a way that secondary metals can be reused more effectively and circular value chains can be better managed. In this way, the project combines materials science issues with digital methods to achieve a resource-efficient circular economy.
The “Circular E-Cars” Graduate College is conducting research on circular value chains for electric vehicles—from dismantling and recycling to the reuse of valuable materials. The focus is particularly on metallic materials, material flows, and new process routes that enable components and materials from electric vehicles to be returned to the cycle in a high-quality manner. The LMW is involved in materials science issues related to recycling, process control, and material quality.
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