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Contributing to lightweight design in the field of metal forming, four different strategies are introduced -the material, component, functional, and conditional lightweight strategy. Their main objective is the reduction of a component's weight and the saving of our available resources. Regarding each approach, innovative forming technologies are presented and their contribution to lightweight success is depicted. On the one hand, this article covers conventional processes like e.g. extrusion, which are used for processing hybrid lightweight materials. On the other hand, new forming technologies are introduced to serve lightweight requirements like e.g. load adaption. Finally, the importance of numerical damage modeling regarding lightweight design is shown.

In this paper, a method for the direct recycling of aluminum scrap by hot extrusion is investigated. 1050 aluminum alloy material in the form of pins remained as scrap after a lateral extrusion process and was mixed with 6060 aluminum alloy chips resulting from a turning operation. Contrary to the conventional method of re-melting aluminum scrap to produce secondary aluminum, this aluminum scrap+chip mixture was cold compacted into billets and hot extruded at 500°C to full rectangular profiles. The extruded profiles were examined by tensile tests and microstructural investigations and compared to the conventionally extruded profiles from as-cast material. It was shown that not only the aluminum chips but also the aluminum scrap material can be recycled directly by hot extrusion, which requires only ~10% of the energy required for recycling by re-melting. Also, the profiles extruded from billets containing 1050 aluminum alloy scrap with and without cooling lubricant were compared and a deteriorating effect was determined.