The REMADE Institute - projects to increase materials sustainability

The Remade Institute is a Manufacturing USA organization focused on accelerating the adoption of the circular economy though the development of cutting edge manufacturing technologies. The goal of REMADE is to make real, near-term environmental and economic impacts by: reducing energy usage through decreased primary feedstock and increased secondary feedstock; improving the embodied energy efficiency; increasing the cost parity of secondary feedstock; and decreasing greenhouse gas emissions and processing energy consumption. These goals are being tackled from the perspectives of manufacturing and design optimization, remanufacturing and recycling implementation, and system analysis.

There are currently over thirty projects in process for metals, polymers, fibers, and e-waste, but this presentation will highlight three that cover a range of technology challenges that are particularly relevant to the IMAT community.

Increasing Efficiency and Secondary Alloy Usage in Aluminum Die Casting – This project used thermodynamic and kinetic modeling to increase the use of secondary alloys in aluminum die casting applications, via improved impurity control and process efficiency.

Quantitative Non-Destructive Evaluation of Fatigue Damage Based on Multi-Sensor Fusion – This exploratory project created an algorithm to estimate the loading levels of aluminum tensile bars using data from linear ultrasonic, non-linear ultrasonic, and acoustic emissions. This technology has the potential to gage the level of fatigue damage in used parts to determine risk associated with reuse.

High Speed Laser Cladding for Hard Surface Replacement – This project is developing a process for the application of 431SS on a 4140 hardened base metal as a case study for the repair of high strength hardened steel shafts. Results will compare the microstructure, heat affected zone, hardness, and bending fatigue strength between high speed and traditional clad samples.

This presentation will promote The REMADE Institute as a source of funding for researchers and a source of solutions for industry.