Optimization and lifecycle engineering for design and manufacture of recycled aluminium parts

Aluminium alloys components are numerous in aeronautic and automobile structures. Despite having interesting mechanical properties for lightweight solutions, the extraction of virgin aluminium still has negative impacts on the environment. A solution is to use an increased rate of recycled aluminium in structural parts. This requires a global optimisation of the part design and manufacture. The proposed work details the advanced optimization techniques used for product and process design integrating environmental concerns. The methodology is implemented and tested on an industrial case that results in a recycling rate of 75% in high-end structural component based on wrought aluminium alloys