Exploring aluminium’s infinite applications: Top 10 scientific innovations highlighting its versatility

Where there is aluminium, there is innovation. Aluminium, once regarded as a mere industrial metal, is now the canvas for some of the most exciting innovations shaping the future. Imaging cars that are lighter than ever, gliding effortlessly with the help of aluminium alloys engineered for strength and agility. More recently, aluminium foil coating has sparked a new hope for microbe-free water purification in African countries. Not just this, Massachusetts Institute of Technology (MIT) engineers have also come up with an interesting discovery to produce 'hydrogen gas' using the green metal. Aluminium is central to innovation across industries, playing a vital role in driving technological advancements and sustainability. Its lightweight yet strong properties make it essential for reducing emissions in automotive and aerospace applications while enhancing performance and energy efficiency. Below is a list of top innovations featuring aluminium as the main component  -

Enhancing drinking water safety with aluminium foil

Waterborne diseases like cholera, typhoid, and diarrhoea are known to harm hundreds of thousands of lives annually in Africa. During such critical scenarios, imagine aluminium foil emerging as the saviour. As per the latest innovation by Taufiq Ihsan, a lecturer at Andalas University in Indonesia and an environmental engineer, he has developed an innovative foil with his colleagues coated with a material called layered double hydroxide (LDH).

This material acts like a magnet, attracting and capturing microbes. In laboratory tests, the LDH-coated foil proved highly effective, removing over 99 per cent of E. coli bacteria—commonly associated with water contamination—from water samples in just a few hours. Beyond E. coli, it also targets a wide range of waterborne pathogens, including bacteria, viruses, and parasites, offering robust protection against multiple waterborne diseases.

Researchers introduced bacteria into clean water in lab tests and immersed the LDH foil to measure its effectiveness. The results were remarkable: the foil eliminated over 99% of the bacteria within 3 to 24 hours. The duration varied slightly depending on the specific formulation of the LDH foil, as each demonstrated different adsorption rates.

Ningbo Shenma Group breakthrough revolution

Ningbo Shenma Group, located in Zhejiang province, has made a major breakthrough in green power transmission with its cutting-edge copper-aluminium composite products. The introduction of copper-aluminium composite products aims to boost the efficiency and sustainability of power transmission systems worldwide. Five years ago, Shenma leveraged its expertise in aluminium production to launch a "copper-aluminium substitution" program, investing over 30 million yuan ($4.19 million) annually in research and development.

This dedication led to the creation of the industry's first copper-aluminium composite plate. The material, with a copper core sandwiched between aluminium layers, uses a unique solid-liquid cast-rolling bonding process, forming a eutectic bond at the interface. This innovation reduces copper usage by nearly half—cutting costs and weight—while improving heat dissipation and maintaining strong conductivity. Its applications span power systems, electrical devices, photovoltaics, and new energy vehicles, offering immense market potential.

Shenma's breakthrough has earned widespread recognition, attracting leading global electrical brands like Schneider, ABB, and Siemens, which now integrate Shenma's copper-aluminium eutectic composite strips into their bus duct products.

AlYN promises more energy-efficient and powerful electronics

Researchers at Fraunhofer IAF have achieved a significant breakthrough in semiconductor materials with the development of aluminium yttrium nitride (AlYN). They successfully fabricated and characterised this promising new material using the MOCVD process. Thanks to its outstanding properties and compatibility with gallium nitride (GaN), AlYN holds immense potential for energy-efficient, high-frequency, and high-performance electronics, particularly in information and communications technology.

Aluminium Yttrium Nitride (AlYN) has garnered significant attention from research groups worldwide due to its exceptional material properties, though its growth has posed a significant challenge. Until recently, AlYN could only be deposited using magnetron sputtering. However, researchers at the Fraunhofer Institute for Applied Solid State Physics IAF have successfully fabricated the material using metal-organic chemical vapour deposition (MOCVD) technology, paving the way for a variety of new applications.

In 2023, the Fraunhofer IAF research team made a breakthrough by depositing a 600 nm thick AlYN layer for the first time. With a wurtzite structure, this layer contained an unprecedented yttrium concentration of over 30 per cent. Recently, the researchers achieved another milestone: they fabricated AlYN/GaN heterostructures with precisely adjustable yttrium concentrations, demonstrating excellent structural quality and electrical properties. These novel heterostructures feature yttrium concentrations of up to 16 per cent. Dr. Lutz Kirste's structural analysis group continues to conduct detailed studies to deepen the understanding of the structural and chemical properties of AlYN.

Nandina REM takes flight with innovative aircraft recycling initiative

Nandina REM, a Singapore-based startup, has launched an innovative recycling initiative to prevent decommissioned airliners from becoming scrap by reclaiming and repurposing their valuable materials. The startup has already proven its concept by successfully reclaiming three large Boeing 767s, with co-founder Cady noting that 90 per cent of the high-value, advanced materials from these planes can be repurposed. As part of its expansion strategy, Nandina now plans to dismantle 40 aircraft.

Their groundbreaking approach not only tackles the growing issue of aircraft waste but also meets the rising demand for sustainable materials in the electric vehicle industry. In the face of climate change, initiatives like Nandina's offer a promising glimpse into a more sustainable future.

Nandina REM's visionary initiative focuses on extracting high-quality aluminium and advanced-engineered materials from decommissioned aircraft to manufacture electric vehicle (EV) battery casings and other essential components. Driven by a mission to reduce environmental pollution significantly, the company aims to contribute to a major reduction in planet-warming emissions.

Through its recycling efforts, the company has set an ambitious target to eliminate one gigatonne (approximately 1.1 billion tonnes) of carbon emissions by 2030. The vast supply of aircraft-grade aluminium alone could produce tens of millions of battery casings, while plastics and other materials can be repurposed into various car parts. Nandina's carbon fibre recycling process also yields a high-strength product that reduces production-related pollution by 71 per cent. This bold plan not only offers hope but also highlights Nandina REM's dedication to environmental sustainability.

Recycling medicine blister pack: Meeting the challenges

In a recent statement, Julien Tremblin, General Manager for TerraCycle Europe, emphasised the need for expanded recycling solutions for empty medicine blister packs. These packs, which play a crucial role in protecting medications, present a significant recycling challenge due to their complex composition and inability to be processed through standard household recycling bins, further complicating the issue.

TerraCycle's innovative recycling process addresses this by separating the plastic and aluminium components of the blister packs, which are typically discarded as general waste. These materials are then transformed into recycled raw materials that can be used to produce new, durable products. For instance, aluminium can be repurposed to manufacture nuts and bolts, while plastic can create pipes and window frames.

Through the TerraCycle BlisterBack initiative, the company is dedicated to creating an extensive network of drop-off points across the UK in the coming months and years. This initiative will offer convenient locations for people to recycle empty medicine blister packs, promoting a sustainable and environmentally friendly approach to waste management.

While medicine blister packs play a vital role in protecting medications within the healthcare sector, recycling them poses significant challenges. These challenges include economic constraints and a lack of adequate recycling facilities, underscoring the urgent need for effective solutions to improve their sustainability.

MIT engineers develop a sustainable method to produce Hydrogen gas

Engineers at the Massachusetts Institute of Technology (MIT), led by Douglas Hart, have made an exciting discovery focused on aluminium, soda cans, and caffeine. They are working on developing efficient, sustainable methods to generate hydrogen gas, a "green" energy source that can power engines and fuel cells without releasing harmful climate-warming gases. Their breakthrough involves exposing pure aluminium from soda cans to seawater, triggering a reaction that produces hydrogen gas. This process can be further accelerated with the addition of caffeine, making it a promising step towards environmentally friendly energy solutions.

The team discovered that while the reaction between aluminium and seawater produces hydrogen gas, it occurs slowly. In an unexpected twist, they added coffee grounds to the mixture and were surprised to see the reaction speed up. Further investigation revealed that a small concentration of imidazole, an active component in caffeine, was enough to accelerate the process significantly. With this stimulant, the reaction could produce the same amount of hydrogen in just five minutes, compared to the usual two hours without it.

In their latest research, the team discovered that they could retrieve and reuse the gallium-indium alloy by using a solution of ions. These ions—charged atoms or molecules—protect the metal alloy from reacting with water and facilitate its precipitation into a form that can be collected and reused. The researchers observed that when they added aluminium to a beaker of filtered seawater, hydrogen bubbles began to form, and they were able to scoop out the gallium-indium afterwards. However, the reaction was much slower in seawater compared to fresh water. This is because the ions in seawater shield the gallium-indium, allowing it to coalesce and be recovered, but they also form a barrier on the aluminium, slowing its reaction with water. The researchers experimented with various unconventional ingredients to accelerate the reaction in seawater.

Optimising CO2 capture with metatitanic acid

In a recent article published in Scientific Reports, researchers introduced a novel adsorbent made of nanoporous metatitanic acid supported on γ-Al₂O₃ aerogel. The aim is to enhance CO₂ adsorption capacity and improve regeneration efficiency. The study explored the optimal conditions for CO₂ capture and the structural characteristics of the synthesised materials, contributing to the advancement of carbon capture technologies.

The research focussed on synthesising and optimising a composite of metatitanic acid (TiO(OH)₂) and γ-Al₂O₃ nanoparticle aerogel for improved CO₂ adsorption. The γ-Al₂O₃ aerogel was prepared using a sol-gel method, where aluminium isopropoxide was hydrolysed in a mixture of ethanol and distilled water at 0°C to control gelation. Polyethylene glycol was incorporated to stabilise the gel structure. After ageing for three days, the gel underwent drying and calcination in two stages: first, heating from ambient temperature to 220°C, and then from 220°C to 600°C to activate the alumina support.

To integrate metatitanic acid, researchers prepared varying ratios of TiO(OH)₂ to γ-Al₂O₃ to optimise CO₂ adsorption. The hydroxyl groups in TiO(OH)₂ enhance CO₂ interaction through chemical bonding, forming titanium carbonate species.

The results revealed that the metatitanic acid/γ-Al₂O₃ aerogel composite exhibited a significantly improved CO₂ adsorption capacity of 12.874 mmol/g under optimal conditions of 20°C, 7 bar pressure, and 25% metatitanic acid by weight. BET analysis showed a high specific surface area and pore volume, crucial for effective gas adsorption. SEM images displayed a well-distributed porous structure, aiding the diffusion of CO₂ molecules into the adsorbent. FT-IR spectra confirmed the presence of functional groups that promote CO₂ interaction, while XRD patterns highlighted the crystalline nature of the metatitanic acid, which is advantageous for the adsorption process.

New approach by SFU scientists

Scientists at the Institute of Non-Ferrous Metals at Siberian Federal University (SFU) have developed an advanced model for casting flat ingots from an economically alloyed aluminium-scandium alloy, initially created at the university for RUSAL. This innovative modelling approach for ingot crystallisation allows Russian manufacturers in industries such as shipbuilding, aerospace, and aircraft production to significantly reduce production costs.

Manufacturers can produce ingots with more uniform structure and composition by using this enhanced model to optimise casting parameters. As a result, products made from these ingots demonstrate improved strength and wear resistance, are less susceptible to failure, and exhibit a notable reduction in manufacturing defects.

The aluminium-based alloys used in the experiment contain the valuable rare earth element scandium, which significantly enhances the products' strength, wear resistance, and durability. While scandium's cost is relatively low in this context, its impact enables the alloys to be used in the manufacture of parts for cars, ships, and aeroplanes, as well as in the construction of rockets and satellites.

The experiments were conducted at a laboratory continuous casting plant and a mini-factory workshop at the Institute of Non-Ferrous Metals at Siberian Federal University. Scientists cast ingots from the aluminium-scandium alloy, measured the necessary temperature and velocity parameters, and integrated these into a mathematical model. Real-world adjustments made during the experiments were then incorporated into the ProCAST software, resulting in an optimised model for ingot crystallisation.

ESA explores the future of in-space manufacturing

Engineers at the European Space Agency (ESA) have closely examined a groundbreaking aluminium weld created in space, marking a historic milestone as the first autonomous welding conducted in orbit and the first of its kind involving ESA. The weld, just one centimetre in size, was produced using electron beam welding technology as part of an experiment led by ThinkOrbital, a US-based startup. The experiment took place aboard a spacecraft launched in May via a SpaceX Falcon 9 rocket.

Now, ESA's Materials and Electrical Components Laboratory in the Netherlands is rigorously analysing the weld. The team is examining the weld's structure and quality using advanced testing tools such as microscopes and X-ray tomography. The findings will be compared with identical samples produced on Earth to assess differences and similarities in material properties and welding outcomes.

This achievement marks a significant advancement for autonomous manufacturing in space, potentially paving the way for future in-orbit construction and repair missions. Welding in microgravity presents a unique challenge, as molten metal behaves differently without the influence of Earth's gravity. NASA and ESA have brought samples of the weld back to Earth for further analysis, with upcoming tests aimed at enhancing in-space manufacturing capabilities even more.

Artificial sapphire insulator developed using single-crystal aluminium

Researchers at the Shanghai Institute of Microsystem and Information Technology, part of the Chinese Academy of Sciences (CAS), have developed a semiconductor chip insulator made from artificial sapphire. This breakthrough could potentially extend smartphone battery life. The study suggests that this atomically thin sapphire film could enable the creation of more efficient two-dimensional circuits.

Led by Di and Tian Ziao from the State Key Laboratory of Materials for Integrated Circuits at CAS, the research team developed a single-crystal aluminium wafer. It introduced oxygen atoms at room temperature to create a 1.25-nanometer-thick single-crystalline aluminium oxide layer. This forms an exceptionally thin layer of artificial sapphire, as reported by SCMP.

This pioneering research also holds promise for more power-efficient chips. In the realm of dielectric materials, transistor miniaturisation has been a significant challenge as devices continue to shrink. Typically, dielectric materials act as insulators in chips, but at the nanoscale, they lose effectiveness—contributing to smartphone overheating and shorter battery life.

Conclusion

In conclusion, aluminium has emerged as a powerful catalyst for innovation, pivotal in driving advancements across multiple sectors. From its application in creating lighter, more energy-efficient vehicles and aerospace components to revolutionising water purification in Africa, aluminium's versatility continues to shine. Breakthroughs such as the copper-aluminium composite products for greener power transmission and the hydrogen production method from soda cans underscore aluminium's importance in developing sustainable solutions. As research and development in aluminium-based innovations continue to grow, the metal's potential to address global challenges and enhance technological progress seems boundless.