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Green Transformation of Steel Scrap into Next-Generation Ultra-High-Strength Steel through Advanced Process Design

Project description

A circular future for green high-strength steel

Ultra-high-strength steel, highly in demand for transport and construction, constitutes about 7 % of all emissions. Supported by the Marie Sklodowska-Curie Actions programme, the REVALORISE-STEEL project aims to implement a paradigm shift towards circular alloy design. Using more than 90 % recycled ferrous scrap as a raw material, the project offers advanced high-strength steels featuring extraordinary strength and ductility. Using machine learning for scoping studies and thermo-mechanical treatments for tailoring complicated multi-phase microstructures, the project ensures sustainable development. The project, however, goes beyond scientific discoveries and implements life cycle assessments to reduce CO2 footprints by at least 60 %.

Objective

Steel remains the backbone of modern industry, but its manufacturing is one of the world's most carbon-hungry process, accounting for over 7% of worldwide emissions. With more effort directed towards achieving net-zero targets and with higher demand for ultra high-strength steels (UHSS) in transport, construction, and defence, there needs to be a radical shift in paradigm away from traditional extractive metallurgy and towards low-carbon, circular alloy design.

REVALORISE-STEEL addresses this by designing a revolutionary next generation of ultra-high strength steel (UTS > 1000 MPa, elongation > 20%), fabricated from over 90% recycled ferrous scrap material. The project targets the development of advanced plain carbon steel through modified multi-phase microstructures (ferrite, martensite, bainite, retained austenite) by the application of novel thermo-mechanical processing (TMP) techniques including hot rolling, intercritical annealing, and quenching & partitioning.

Among the innovations is using machine learning-based scoping of alloys with TMP verification via experimentally validated methods, accelerating alloy discovery and tailoring required microstructure and mechanical properties. The approach is based on deep understanding of phase transformation, microstructure evolution, corrosion resistance, and weldability. My research will target guiding model development, optimizing alloy processing, and performance validation against industrial standards.

Life Cycle Assessment (LCA) and techno-economic studies will evaluate the economic and environmental viability of these alloys, aiming to reduce the carbon content by over 60% compared to conventional Advanced High-Strength Steels (AHSS).

Supported by Imperial College London and industry collaborators and aligned with the UN Sustainable Development Goals (SDG 9, 12, and 13), this project is pioneering sustainable, circular steelmaking.

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HORIZON-TMA-MSCA-PF-EF - HORIZON TMA MSCA Postdoctoral Fellowships - European Fellowships

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Call for proposal

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(opens in new window) HORIZON-MSCA-2025-PF

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Coordinator

IMPERIAL COLLEGE OF SCIENCE TECHNOLOGY AND MEDICINE
Net EU contribution

Net EU financial contribution. The sum of money that the participant receives, deducted by the EU contribution to its linked third party. It considers the distribution of the EU financial contribution between direct beneficiaries of the project and other types of participants, like third-party participants.

€ 276 187,92
Address
SOUTH KENSINGTON CAMPUS EXHIBITION ROAD
SW7 2AZ London
United Kingdom

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Region
London Inner London — West Westminster
Activity type
Higher or Secondary Education Establishments
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Total cost

The total costs incurred by this organisation to participate in the project, including direct and indirect costs. This amount is a subset of the overall project budget.

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