The iron and steel sector is one of the most difficult-to-decarbonize industries due to its reliance on blast furnaces for steel production. Recycling steel via the electric arc furnace (EAF) route is critical for decarbonization, as recycled steel has a carbon footprint one-third that of primary steel. However, producing high-value products like strip, sheet, and wire from recycled end-of-life (EOL) scrap is hindered by residual elements, especially copper (Cu). Cu which enters scrap primarily from electrical wiring is difficult to remove due to its low affinity for oxygen and causes surface embrittlement during high-temperature processing of steel, such as in hot rolling. This phenomenon is referred to as surface hot shortness. With the increasing use of copper in vehicles, particularly electric vehicles (EVs), this issue is expected to become a critical bottleneck for steel recycling.This doctoral dissertation presents a novel manufacturing method, known as metal peeling, to produce high-quality steel strips and wire directly from recycled EOL steel. Unlike traditional rolling, metal peeling involves peeling or machining a thin continuous strip from a rotating cylindrical feedstock without requiring bulk heating of the metal. Although local temperatures in the peeling zone might be of the order of 1,000 °C, the exposure time is extremely brief, 100 microseconds or less. This effectively suppresses copper diffusion and surface embrittlement. We hypothesize that this method enables steel strip production from recycled steel with high Cu levels and other residual elements.The dissertation addresses five specific technical objectives building on the scientific principles drawn from mechanics, metallurgy, and modeling of transport phenomena (heat and mass diffusion) : (1) demonstrating the feasibility of metal peeling with high Cu-containing steels (up to 2 wt.% Cu) to produce high-quality strips without surface cracking; (2) developing a model for Cu enrichment during peeling to identify theoretical bounds on the level of Cu that can be tolerated in peeling; (3) utilizing Cu precipitation hardening to strengthen low-carbon mild steels; (4) quantifying the energy and carbon emissions savings of recycled/metal peeling approach compared to the blast furnace/hot rolling route; and (5) extending the metal peeling concept for wire production. Besides addressing a long-standing sustainability problem in the iron and steel sector, this work contributes to the development of an energy-efficient, clean and a low-cost approach for metal sheet and wire production.