Upcycled high-strength aluminum alloys from scrap through solid-phase alloying

Area of Science:

• Materials Science
• Metallurgical Engineering
• Sustainable Manufacturing

Background:

• Traditional secondary aluminum recycling via melting has limitations in alloy composition and microstructure control.
• Melt-based processes restrict the properties and applications of recycled aluminum products.
• Energy savings from secondary aluminum recycling are significant but can be further optimized.

Purpose of the Study:

• To develop an alternative to melt-based recycling for aluminum.
• To create a high-performance aluminum alloy from recycled scrap.
• To enable simultaneous alloying during the recycling process.

Main Methods:

• Development of a solid-phase recycling and simultaneous alloying technique.
• Alloying of 6063 aluminum scrap with copper, zinc, and magnesium.
• Characterization of the resulting nanostructure and mechanical properties.

Main Results:

• Formation of a nanocluster-strengthened aluminum alloy with properties similar to 7075 aluminum alloy.
• Achieved a high density of Guinier-Preston zones and nanoscale strengthening phases.
• Yield and ultimate tensile strength increased by over 200%.

Conclusions:

• Solid-phase recycling offers a viable method to upcycle aluminum scrap into high-performance materials.
• The developed process overcomes limitations of traditional melt-based recycling.
• This scalable approach provides a model for sustainable metal reuse and on-demand upcycling.