Raw Material Criticalities and Furnace Selection Choices in Aluminum Casting: A Pathway to Sustainable Foundries

The aluminum casting industry plays a pivotal role in modern manufacturing, contributing to sectors such as automotive, aerospace, and construction. However, the increasing demand for aluminum, coupled with environmental concerns, necessitates a critical evaluation of its raw material sourcing and energy-intensive casting processes. This study explores the dual challenges of raw material criticalities and furnace selection choices in primary and secondary aluminum casting, aiming to chart a pathway toward more sustainable foundry practices. The study is based on the definition of criticality and environmental assessments for a more circular and climate-resilient future. Raw material criticality assessment is assessed through six factors: (1) abundance of elements in the Earth’s crust, (2) sourcing and geopolitical risk, (3) environmental country risk, (4) supply risk, (5) economic importance, and (6) recycling input, while the environmental assessment is made through two major loads: (i) embodied energy, and (ii) carbon footprints. A comparative analysis of common furnace types, including crucible, induction, reverberatory, and stack furnaces, with varying in-house return rates, is conducted to examine the trade-offs in performance from a sustainability perspective. The findings of the proposed work will emphasize the importance of material and process selection in foundries to save the reserves of critical raw materials, implement better closed-loop recycling systems, integrate renewable energy sources, and develop smart furnace operations to minimize environmental footprints. This comprehensive approach is vital for transitioning the foundry industry toward a more circular and climate-resilient future.