Preparation of Al-Si alloys with silicon cutting waste from diamond wire sawing process

Large amounts of silicon cutting waste (SCW) are generated during Si wafers producing process. In this paper, SCW was mixed with Al powder to prepare Al-Si alloys by a one-step smelting process in corundum crucibles. The influences of smelting temperature (1000 °C, 1200 °C and 1500 °C) on the products of each zone (surface layer zone, loose granular zone and blocky products zone) were investigated. Al-Si alloys in the form of granular and blocky were prepared and the blocky Al-Si alloys mainly concentrated in the blocky products zone. The increase of smelting temperature can promote the aggregation of Al-Si alloy particles. The yields of Al-Si alloy blocks obtained at 1000 °C, 1200 °C and 1500 °C were 0%, 58% and 69%, respectively. The Si contents of Al-Si alloy blocks at 1200 °C and 1500 °C were 15.8 wt% and 17.1 wt% respectively. After compacting the raw materials, the yields of the blocky Al-Si alloys obtained at 1000 °C, 1200 °C and 1500 °C were increased to 65%, 72% and 79% and the corresponding Si contents of the blocky Al-Si alloys were increased to 16.0 wt%, 16.5 wt% and 17.3 wt% respectively. The reaction mechanism of the alloying process was also investigated.