-        Development of recycled high‑quality steel from scrap

-        A drastic reduction in CO₂ emissions

-        Strengthening of the circular economy in Europe

-        Research into the (commercial) applicability of fully recycled steel in 

         cars and washing machines

A key research goal of CiSMA is to achieve a 70% overall reduction in CO₂ emissions in sheet steel production through the use of 100% scrap and EAF technology. Using 100% scrap in steel production is not yet a realistic scenario and depends on many factors, such as the availability of scrap. However, participating in this research provides valuable insights for producing high‑quality steel that contains 30 to 40% scrap.

Machine Learning and digital models are also being used to examine to what extent contaminated scrap can be cleaned for optimal reuse. This requires removing unwanted elements from the scrap. Dr. Rana: “If we succeed, this will be a real win‑win, also because of the critical raw materials such as copper, we will be able to recover.”

Alongside universities and research institutes, CiSMA brings together commercial partners from various sectors including automotive, professional laundry equipment and engineering. Volvo Cars and Electrolux Professional, for example, are researching the (commercial) applicability of this recycled steel in cars and washing machines whilst boosting a circular approach and reducing CO₂ impact. The guiding principle is that this circular steel offers exactly the same properties and performance as traditionally produced high‑quality steel. Dr. Johan Pilthammar, Engineering Technical Specialist at Volvo Cars adds: “It’s very important for Volvo Cars to understand if, and how, a higher recycled content is influencing the steel’s behaviour. This project is of high value for us since it will verify that this assumption holds for the investigated steel grades in the forming process. Also, if we see differences with a higher recycled content, we will learn how to adapt to these changes.”

“Electrolux Professional remains wholly committed to reducing the climate change impact of our industrial operations. Steel is a key material in our production process and exploring innovative ways of introducing a greater level of circularity is of significant strategic importance to reducing our upstream Scope 3 emissions”, states Andrea Caputo, Sustainability Director BA Laundry, at Electrolux Professional. He concludes: “The CiSMA project has the potential to deliver truly game-changing results, and we are excited to participate in what is likely to be a landmark pilot test.” 

CiSMA is coordinated by Eurecat (Spain) and consists of 13 partners from five countries, including voestalpine, Volvo Cars, Electrolux Professional, RISE, Blekinge Institute of Technology, ALBA Synchrotron, Aerobase Innovations, the European Steel Technology Platform ESTEP, CSIC, the University of Liège and Tata Steel Nederland. CiSMA has a total budget of nearly €4.5 million and is funded through the EU’s Horizon Europe programme.

·       Safety: the combination of high strength and high formability resists the impact of collisions;

·       Energy efficiency: the steel is hot-formed at lower temperatures;

·       More corrosion protection: thanks to a specific zinc coating that does not crack during hot-forming;

·       Cost savings: due to less tool wear and fewer post‑processing steps. 

Lower energy consumption and improved passenger safety 

Ultra-strong steels used in automotive crash structures are usually hot-formed at very high temperatures. At those temperatures, the zinc coating on the steel can melt, resulting in cracking. For that reason, manufacturers often use aluminium‑silicon coated steels. Those can withstand high temperatures but offer lower corrosion resistance. “By developing this new high‑quality steel grades, we address these limitations,” says Dr. Radhakanta Rana, metallurgist at Tata Steel Nederland and project leader of WarP-AHSS. Dr. Rana explains: “The benefits go beyond energy savings alone. By combining ultra-high strength with exceptional in-service formability, these new steels can absorb significantly more crash energy. This reduces the effect of a collision and increases passenger safety. It is a true breakthrough in steel design and aligns with Tata Steel Nederland’s strategy for more sustainable steel production.” 

Less maintenance and lower production costs 

These new steel grades also offer various benefits for automotive manufacturers. A zinc coating, processed at lower temperatures, eliminates the need for additional processes such as sand‑blasting and provides improved corrosion resistance. This leads to a simpler, more efficient production process, less maintenance, and lower production costs. Dr. Christina Sunderkötter, Project Manager Sustainability Solutions from Volkswagen Group adds: “In addition to reducing environmental impact, we want to offer a steel solution that meets the requirements of future vehicle production: better safety performance, simpler manufacturing processes, and lower part-making costs. Together through WarP‑AHSS, we are working on the next evolution in AHSS technology.” 

WarP-AHSS is funded by the European Research Executive Agency (REA) on behalf of the European Commission. The project runs from 2023 until 2027.

Photo by: David de Jong

Did you know, for example, that each year in IJmuiden we produce enough steel for one and a half million cars? And that for the automotive industry alone, we offer eighty different types of steel, each with its own mix of characteristics: lightweight, safe, formable, or aesthetically flawless.

Paper-thin and extremely strong

It all starts with pig iron and steel scrap. We melt these into liquid steel. Then come casting, rolling, and hot-dip galvanizing. The result: high-quality automotive steel — usually paper-thin, and sometimes extremely strong or extremely formable. Innovations like MagiZinc make steel extra corrosion-resistant, while Advanced High-Strength Steel is so strong that car parts can be made thinner. And because the parts are thinner, the car becomes lighter as well. An added bonus? You need less fuel, which means lower CO₂ emissions.

Innovation Lab

Together with car manufacturers, we push steel to its limits in our R&D Innovation Lab. Think crash testing, formability, paintability — we check it all. From crash boxes to battery housings, from complex body parts to glossy body panels: every component gets exactly the right steel.

Precision and safety

We also want to continuously optimize our production processes, for example through DRI-EAF. This brings us ever closer to a CO₂-neutral future, without having to compromise on quality or safety.

Like this? Then also read:

• Steel is everywhere: From tractor to forklift, from radiator to washing machine
• Our promiss to the planet to become carbon-neutral
• Packaging: don't throw it away - reuse it 

HM King Willem-Alexander receives an explanation of the different steel types in a car during our 100-year anniversary

At the innovation centre, Nico Langerak explains how the steel folds during a collision. 

Our innovations not only make these smart structures possible, but also enable us to make stronger steel. Steel that keeps passengers safe.

The full article can be read in issue 14 of Autoweek (2025), and on the Autoweek website.