Current project „REAL-USS“: Recycled aluminium for electromobility

Chemnitz University of Technology has been working on the project „REAL-USS - Recycled Aluminium for Ultrasonic Welding for Electromobility“, co-financed by the EU and the Free State of Saxony, since 01.07.2025. The project is funded as part of the Just Transition Fund (JTF) through the „InfraProNet 2021–2027“ programme.

The aim of the project is to develop a recycling technology for aluminium that makes it possible to produce wires that are suitable for ultrasonic metal welding (USMW) and can therefore be used in electrical connections, particularly in electromobility. USMW is regarded as a key technology for the production of highly conductive, material-locking connections without filler materials, for example in cable harness connections in electric and hydrogen vehicles.

While primary aluminium has been used almost exclusively for such applications to date, there is a lack of processes that can provide secondary aluminium with the required electrical and mechanical properties. REAL-USS aims to close this gap and thus make an important contribution to the circular economy, CO2 reduction and the sustainable use of raw materials. In the interdisciplinary project, the professorships of Materials and Surface Technology (WOT), Composites and Material Composites (PVW) and Adaptronics and Lightweight Functional Design (AFL) are working together on the entire process chain, from recycling and wire drawing to welding processing and validation. The project is supported by regional industrial partners, including CMMC GmbH and KIESELSTEIN International GmbH, who are contributing their expertise in melting metallurgy and wire drawing processes.

REAL-USS is therefore not only technologically ambitious, but also contributes to strengthening Chemnitz as a centre of research and innovation. The project is in line with the strategic goals of the Free State of Saxony to establish closed raw material cycles and resilient, resource-conserving production. We would like to thank the Just Transition Fund, the European Union and the Free State of Saxony for supporting this project.

Image: The REAL-USS project is paving the way for the use of recycled aluminium in ultrasonic metal welding (Graphic: Andreas Gester/PVW)

7.11.2025 – Projects of the professorship ( thomas.grund@mb… )