Background Metal chips of light alloys – such as aluminium (Al) and titanium (Ti) alloys – are a common industrial waste product. Recycling these chips brings economic and environmental benefits through the reuse of metal resources. However, recycling is difficult because the chips are heavily contaminated by the lubricant/coolant used during processing and highly oxidised on the surface as a result of the high temperatures generated by the workpiece and the tool. The problem of surface contamination of chips of metal is greater given their high surface to volume ratio. The removal of the lubricants/coolants and of the oxidised layer is fundamental for the proper recycling of these metals. It is currently done by washing the chips in an ultrasonic bath with detergent solutions and then final pickling using acids. But this process not only creates hazardous wastewater, it also dissolves oxide and part of the metal. Objectives The LIFE NATURe project aims to demonstrate a new, environmentally friendly process for recycling light alloy chips that are oxidised or contaminated by lubricants or coolants. It aims to use the recycled metal in the production of high-quality wire made with an outer shell of recycled light alloys. The project will design, develop, test and optimise a drawing and co-extrusion demonstration system dedicated to Al or Ti alloys. This system will be based on initial studies of the ‘extrudability’ and reactivity of Al and Ti chips deriving from different types of processes. The system will treat even partially oxidised or contaminated alloys without the use of detergents and pickling substances. The team will modify a standard drawing line for the production of steel wires with greater surface roughness to maximise adhesion of the outer coating at lower processing temperatures and without the need for hot-dip galvanising. It will modify the operating parameters of the cutting machine and electric welder for the manufacture of high-performance mesh and optimise the final annealing process. It will conduct an overall energy and environmental assessment of the new process. The project hopes to demonstrate wire and welded wire mesh of increased durability, especially in the most extreme applications, compared to normal galvanised wire. This should reduce the dispersion of zinc oxide into the environment and increase the lifespan of the product. The products will be tested in severe corrosion conditions, such as those provided in the marine environment. Expected results: Demonstration of a production process for recycling light alloy chips even if partially oxidised or contaminated by lubricants/coolants with capacity of 133 to 224 kg of chips per year; Valorisation of waste light alloy chips in the production of wire and electro welded mesh of increased durability, scratch resistance and corrosion protection compared to normal galvanised wire; Reduced energy consumption and vapour emissions from lower processing temperatures; Avoidance of hazards associated with use of detergents and pickling substances as well as hot-dip galvanising; Reduced consumption of primary raw materials in the production of wire and wire mesh and reduction of associated economic costs, notably of zinc slabs; and Improved lifecycle performance of wires through longer life and reduced dispersion of zinc oxide to the environment from corroding wires.Results This section will be completed once the project has finished. In the meantime for full information about on-going work and progress, please visit the project web site: www.sacmesrl.com