Development of a new class of Al-Cu alloys with critical raw materials recycled from lithium-ion batteries.

• Grant number: 24/21990-3
• Support Opportunities: Scholarships in Brazil - Post-Doctoral
• Start date: October 01, 2025
• End date: September 30, 2028
• Field of knowledge: Engineering - Materials and Metallurgical Engineering - Transformation Metallurgy
• Principal Investigator: José Augusto de Oliveira
• Grantee: Talita Almeida Vida de Brito
• Host Institution: Faculdade de Engenharia. Universidade Estadual Paulista (UNESP). Campus São João da Boa Vista. São João da Boa Vista , SP, Brazil

Abstract

The growing demand for lithium-ion batteries (LIBs) and the environmental impacts associated with their improper disposal pose critical challenges to industrial sustainability. Hydrometallurgical recycling of these batteries enables the efficient recovery of strategic metals such as lithium (Li), manganese (Mn), and cobalt (Co). However, a significant scientific gap remains regarding the direct reuse of these elements as alloying additions in high-performance applications. This project proposes a novel and integrated approach to investigate the metallurgical potential of these recovered metals by incorporating them into the formulation of Al-4.5wt.%Cu alloys to meet the stringent microstructural, mechanical, and electrochemical requirements of the aerospace industry. The proposal includes the experimental production of modified aluminum alloys using recovered metals, previously obtained as metallic powders through a validated hydrometallurgical route. The resulting materials will undergo detailed microstructural, mechanical, and electrochemical characterization. A direct comparison will be made between alloys produced with recycled metals and those fabricated with commercial-grade elements to assess the technical feasibility of using recycled inputs as viable substitutes in producing high-value structural materials. Additionally, a Life Cycle Assessment (LCA) will be conducted following ISO 14040 guidelines, utilizing primary and secondary data to quantify the environmental impacts and eco-efficiency of the alloys produced, reinforcing the commitment to sustainable manufacturing pathways. By aligning materials science, sustainability, and technological innovation, this research aims to make an original contribution to circular economy strategies and national technological autonomy, in line with the Sustainable Development Goals (SDGs 9, 12, and 13) and the directives of the New Brazilian Industrial Policy. Ultimately, the project seeks to demonstrate the technical and environmental feasibility of a new route for reusing critical metals recovered from technological waste, fostering the integration of advanced recycling with the development of aerospace-grade aluminum alloys. (AU)