Daniel R. Cooper

Reusing steel and aluminum components at end of product life

Reusing steel and aluminum components would reduce the need for new production, possibly creating significant savings in carbon emissions. Currently, there is no clearly defined set of strategies or barriers to enable assessment of appropriate component reuse; neither is it possible to predict future levels of reuse. This work presents a global assessment of the potential for reusing steel and aluminum components. A combination of top-down and bottom-up analyses is used to allocate the final destinations of current global steel and aluminum production to product types. A substantial catalogue has been compiled for these products characterizing key features of steel and aluminum components including design specifications, requirements in use, and current reuse patterns. To estimate the fraction of end-of-life metal components that could be reused for each product, the catalogue formed the basis of a set of semistructured interviews with industrial experts. The results suggest that approximately 30% of steel and aluminum used in current products could be reused. Barriers against reuse are examined, prompting recommendations for redesign that would facilitate future reuse.

Note on the Rate and Energy Efficiency Limits for Additive Manufacturing

We review the process rates and energy intensities of various additive processing technologies and focus on recent progress in improving these metrics for laser powder bed fusion processing of metals, and filament and pellet extrusion processing of polymers and composites. Over the last decade, observed progress in raw build rates has been quite substantial, with laser metal processes improving by about 1 order of magnitude, and polymer extrusion processes by more than 2 orders of magnitude. We develop simple heat transfer models that explain these improvements, point to other possible strategies for improvement, and highlight rate limits. We observe a pattern in laser metal technologies that mimics the development of machine tools; an efficiency plateau, where faster rates require more power with no change in energy nor rate efficiency.

Why we use more materials

In this paper, we review the drivers for the high levels of material use in society, investigating both historical and current trends. We present recent national and global data by different material categories and accounting schemes, showing the correlations between materials use and different measures of human well-being. We also present a development narrative to accompany these observed trends, focusing on the strong role materials have played in economic development by industrialization and in the consumer economy. Finally, we speculate on how material efficiency might alter this pattern going forward and whether it is possible to de-couple well-being from material use. This article is part of the themed issue ‘Material demand reduction’.