Remanufacturing process chain for end-of-life aluminium car body parts: Technical and economic analysis

Abstract. This paper investigates the potential for remanufacturing aluminium sheets from end-of-life vehicles (ELVs), specifically focusing on car hoods. The study explores various pre-flattening procedures and reshaping techniques, with warm flattening showing promise despite challenges such as paint degradation. A Design of Experiment (DoE) was used to assess the impact of various factors on the flattening process, and Finite Element (FE) simulations were used to validate the experimental findings. An economic feasibility analysis was also conducted, which revealed that while technically feasible, the economic viability of this remanufacturing process is currently challenging due to the high costs compared to purchasing new sheets. However, with the increasing use of aluminium in automotive body panels and potential market shifts, these remanufacturing initiatives could become economically viable in the future, contributing to sustainability goals in the automotive sector.