Advancing Circularity in Aerospace: Airbus’s Initiatives for Titanium and Aluminium Recycling

The aerospace sector is undergoing a pivotal shift toward sustainable manufacturing, and Airbus is at the forefront of this change. With global pressure mounting to reduce environmental footprints, particularly in resource-intensive industries like aviation, circularity has emerged as a strategic imperative. Airbus is leveraging advanced technologies and forging new partnerships to increase the circularity of two critical metals, titanium and aluminium, used extensively in aircraft manufacturing.

Through innovations such as additive layer manufacturing (ALM), targeted recycling programs, and collaborations across the value chain, Airbus aims to reduce raw material consumption, extend component life, and ensure high-quality recycling of metals at the end of an aircraft’s service. These initiatives not only cut emissions but also address long-term supply chain vulnerabilities and align with broader sustainability goals, like those outlined in the Destination 2050 roadmap.

The Importance of Circular Economy in Aerospace

The circular economy represents a fundamental departure from the traditional linear model of production and consumption. In aerospace, where aircraft are designed to last over two decades, resource efficiency has always been a consideration. However, the scale and urgency of climate change have elevated the importance of circularity, particularly for high-impact materials like titanium and aluminium.

Circularity in this context involves more than just recycling. It encompasses a full spectrum of strategies, the ‘ten Rs’, which include refusing unnecessary use, reducing material input, rethinking design, reusing components, repairing, refurbishing, repurposing, remanufacturing, recycling, and recovering. For metals, this approach is especially valuable, as they can theoretically be recycled indefinitely without loss of integrity.

Despite this potential, demand for virgin metals still outpaces the uptake of recycled materials. This is due to several factors, including the technical challenges of reclaiming aerospace-grade metals and regulatory hurdles that prioritize traceability and performance standards. Airbus’s initiatives aim to close this gap by embedding circularity throughout the aircraft lifecycle, from design to decommissioning.

Why Titanium and Aluminium Matter

Titanium and aluminium are foundational to modern aircraft design. Titanium is prized for its strength, corrosion resistance, and ability to withstand high temperatures, making it ideal for engines, landing gear, and structural components. Aluminium, on the other hand, is lightweight and malleable, commonly used in fuselage structures, wing assemblies, and interior components.

The use of these metals contributes significantly to aircraft performance, particularly in reducing weight and improving fuel efficiency. For example, the Airbus A350 incorporates a high percentage of aluminium and titanium in its airframe, contributing to a 25% reduction in fuel burn compared to previous models.

However, the environmental cost of producing these metals is considerable. Primary aluminium production is energy-intensive, while titanium extraction and processing emit substantial greenhouse gases. Increasing the use of recycled materials can mitigate these impacts, but only if high-quality recycling processes are in place to maintain the stringent standards required in aerospace applications.

Technological Innovations at Airbus

Additive Layer Manufacturing (ALM)

One of Airbus’s most promising technologies for enhancing material circularity is additive layer manufacturing (ALM), a form of 3D printing. Unlike traditional subtractive manufacturing, which cuts away material from a larger block, ALM builds parts layer by layer, using only the material necessary. This substantially reduces waste and allows for more complex, integrated designs.

Airbus employs two main ALM techniques: powder bed fusion (PBF) and directed energy deposition (DED). PBF uses lasers to melt powdered titanium into precise shapes, while DED involves melting wire feedstock to create larger, regularly shaped parts. These methods have already yielded tangible benefits. For instance, the latch shafts on the A350, previously made from ten separate parts, are now produced as a single component using ALM, reducing weight by 45% and saving approximately 126,000 kg of CO₂ over the aircraft’s lifespan.

These innovations not only improve material efficiency but also contribute to structural integrity and performance. The integrated designs made possible through ALM reduce assembly complexity and potential failure points, enhancing safety while supporting sustainability goals.

“With ALM, we’re not just reducing waste, we’re rethinking how parts are designed, manufactured, and integrated. It’s a paradigm shift in aerospace engineering.”, Airbus Engineering Team

Recycling and Recovery

Airbus is also investing in advanced recycling technologies that allow for the recovery of high-quality titanium and aluminium from decommissioned aircraft. Partnering with organizations like TARMAC Aerosave and Constellium, Airbus has developed processes to disassemble aircraft and sort materials for reuse. These efforts are supported by digital material passports that track the composition and history of each part, ensuring traceability and compliance with aerospace standards.

For aluminium, this has led to the successful remelting of reclaimed material into certified aerospace-grade sheets. These sheets match the mechanical properties of virgin aluminium but require only 5% of the energy to produce. For titanium, Airbus works with IMET Alloys, which uses chemical cleaning processes to remove contaminants from used parts, enabling up to 95% of the recovered metal to be reused in new manufacturing.

These advancements are crucial in closing the loop for aerospace metals. By ensuring that materials retain their value and performance characteristics, Airbus is creating a more resilient and sustainable supply chain while reducing reliance on energy-intensive virgin material production.

Collaborative Ecosystem and Partnerships

Airbus recognizes that achieving true circularity requires collaboration across the entire aerospace value chain. The company works closely with raw material suppliers, component manufacturers, recycling specialists, and regulatory bodies to develop and implement circular practices. These partnerships are essential for overcoming technical, logistical, and regulatory challenges.

For example, IMET Alloys plays a key role in processing and recycling titanium scrap, while Constellium focuses on aluminium recycling. TARMAC Aerosave specializes in aircraft dismantling and material recovery. Together, these partners help Airbus achieve high recovery rates and ensure that recycled materials meet the stringent requirements of aerospace manufacturing.

These collaborations also facilitate knowledge sharing and innovation. By pooling expertise and resources, Airbus and its partners are able to develop new technologies, improve recycling efficiency, and accelerate the adoption of circular practices across the industry.

Conclusion

Airbus’s commitment to increasing the circularity of titanium and aluminium represents a significant step forward in sustainable aerospace manufacturing. Through the use of additive manufacturing, advanced recycling techniques, and strategic partnerships, the company is setting new standards for resource efficiency and environmental stewardship.

As the aerospace industry continues to grow, the need for sustainable material management will become even more critical. Airbus’s initiatives provide a blueprint for how companies can reduce their environmental impact while maintaining performance and safety. Looking ahead, further innovations in design, regulation, and collaboration will be key to scaling these efforts and achieving a truly circular aerospace economy.

FAQ

What is circularity in aerospace manufacturing?
Circularity refers to a production model that minimizes waste and maximizes the reuse, recycling, and recovery of materials throughout the lifecycle of an aircraft.

Why are titanium and aluminium important in aircraft?
These metals are lightweight, strong, and resistant to corrosion. Titanium is used in high-stress components like engines and landing gear, while aluminium is widely used in fuselage and wing structures.

How does additive manufacturing reduce waste?
Additive manufacturing builds parts layer by layer, using only the material needed. This reduces scrap and allows for more efficient and integrated designs.

Can recycled metals meet aerospace standards?
Yes, with proper processing and certification, recycled titanium and aluminium can meet the stringent performance and safety requirements of aerospace applications.

What are the environmental benefits of circularity?
Recycling metals significantly reduces energy use and emissions compared to producing new materials. For example, recycled aluminium uses up to 95% less energy than primary production.

Sources:
Airbus,
IMET Alloys,
Constellium,
TARMAC Aerosave,
Ellen MacArthur Foundation