Material Flow Recovery

Despite the efficient manufacturing methods developed in the SCALE project, complete material utilisation is not achieved during machining operations. Particularly with high-value materials such as titanium, the resulting chips are currently only suitable for downcycling and not reused as raw material for new, high-quality components.

Research Focus Area 3 therefore investigates efficient, high-quality material flow recovery to further reduce losses in both energy and material cycles. Starting with chips generated during machining, their recyclability is to be enhanced through targeted analysis and process optimisation.

Key research questions address how the material properties of different alloys change during machining and what impact this has on their recyclability. For resource-efficient reintegration into the melting process, forming techniques for pre-compacting chip material into melting electrodes are examined. Depending on chip type and process parameters such as compaction pressure or shaking volume, briquettes of varying density and quality are produced.

Through the coordinated interplay of machining, forming, and atomisation, high-quality powder for additive manufacturing can subsequently be obtained. Additionally, the potential of coating chip briquettes with high-purity metal powders to further enhance powder quality is being evaluated.