Session: DFMLC-03-01-Design for Supply Chain and End of Life Recovery

Paper Number: 97922

97922 - The Clean Sheet Project: A Potential Template for Increasing End-of-Life Recycled Contents Across Material Systems 

End-of-life recycling rates greater than 90% are a necessary condition of industrial decarbonization in line with the IPCC’s 1.5-2 °C targets. However, there are technical barriers to the high-value recycling of many materials such as wrought alloys and multiple polymers. In this talk, we will discuss the multidisciplinary cross life-cycle approach being implemented in a new project focused on design and processing options for high‐value recycling of advanced aluminum and steel automotive sheets. This is a U.S. Department of Energy supported collaborative project between the University of Michigan, Argonne National Lab, Ford Motor Company, Novelis, The Aluminum Association, Institute of Scrap Recycling Industries, and Light Metal Consultants. We will present an overview of the approach, including the development of a design optimization tool that couples the effect of vehicle design, recycling system practices and technologies, and alloy compositional tolerances, under different ecosystem scenarios from 2020‐2050 (e.g., continued internal combustion engine dominance vs. rapid deployment of electric vehicles). For each stage of the life cycle, we explore the limits of the design space through, for example, using Integrated Computational Materials Engineering to examine the potential to use alternative materials processing to achieve satisfactory material properties from suboptimal compositions, re-examining the user requirements that guide material specifications, and predicting the effect of emerging as well as established recycling technologies on end-of-life material streams. Throughout, we will discuss the potential and limitations of applying this approach to other material systems.

Presenting Author: Daniel Cooper University of Michigan

Presenting Author Biography: Dan Cooper is an Assistant Professor in the Mechanical Engineering department at the University of<br/>Michigan. He heads the Resourceful Manufacturing and Design (ReMaDe) group, which is dedicated to<br/>pursuing environmental sustainability through process innovations in resource efficiency and optimized<br/>manufacturing and recycling supply chains. Dan’s work is at the nexus between Industrial Ecology (IE)<br/>and Mechanical Engineering (ME): he uses and develops IE methodologies such as material flow analysis<br/>and life cycle assessment to identify opportunities and quantify impacts at the process, factory, and<br/>supply chain scale, and then pursues an experimental and mechanistic modeling approach to generate<br/>the scientific knowledge underlying those opportunities. Dan received all his degrees in Mechanical<br/>Engineering from the University of Cambridge before completing a post‐doc at MIT. He is the recipient<br/>of the ASME Ben C. Sparks Education Medal and the SME Outstanding Young Manufacturing Engineer<br/>Award.

Authors:

Daniel Cooper University of Michigan