Data-Driven Modeling of Composition-Processing-Microstructure Relations for Recycled Aluminum Cast Alloys.

Area of Science:

• Materials Science
• Metallurgy
• Sustainable Manufacturing

Background:

• Aluminum is a critical global metal, vital for industries like transportation and construction.
• Recycling aluminum significantly reduces energy consumption (up to 95%) and supports low-carbon manufacturing goals.
• Recycled aluminum often contains higher iron levels, leading to brittle phases that compromise material performance and limit applications.

Purpose of the Study:

• To differentiate between phase type formation and its impact on material behavior in aluminum alloys.
• To develop practical guidelines for controlling deleterious iron-rich phases in recycled aluminum.
• To enable more quantitative and predictable alloy design for sustainable aluminum.

Main Methods:

• Analysis of alloy chemistry and processing history data representative of industrial conditions.
• Separation of the questions regarding phase type formation and its subsequent effect on material properties.
• Investigating the influence of composition and processing on the morphology (platelet-like vs. compact particles) of iron-rich phases.

Main Results:

• Alloy chemistry and processing history were shown to dictate the specific type of iron-rich phase that forms.
• These factors also govern the morphology of the phases, determining if they appear as large platelets or small particles.
• A clear distinction was established between phase formation and its impact on material behavior.

Conclusions:

• The study provides a framework to mitigate detrimental iron-rich phases in recycled aluminum alloys.
• This research facilitates more predictable and impurity-tolerant sustainable alloy design.
• Understanding the distinct roles of composition and processing enables enhanced control over material performance.