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

Author

Listed:
  • Tianhao Wang

    (Pacific Northwest National Laboratory)

  • Xiao Li

    (Pacific Northwest National Laboratory)

  • Zehao Li

    (Pacific Northwest National Laboratory)

  • Tingkun Liu

    (Pacific Northwest National Laboratory)

  • Xiang Wang

    (Pacific Northwest National Laboratory)

  • Arun Devaraj

    (Pacific Northwest National Laboratory)

  • Cindy A. Powell

    (Pacific Northwest National Laboratory)

  • Jorge F. Santos

    (Pacific Northwest National Laboratory)

Abstract

Although recycling secondary aluminum can lead to energy consumption reduction compared to primary aluminum manufacturing, products produced by traditional melt-based recycling processes are inherently limited in terms of alloy composition and microstructure, and thus final properties. To overcome the constraints associated with melting, we have developed a solid-phase recycling and simultaneous alloying method. This innovative process enables the alloying of 6063 aluminum scrap with copper, zinc, and magnesium to form a nanocluster-strengthened high-performance aluminum alloy with a composition and properties akin to 7075 aluminum alloy. The unique nanostructure with a high density of Guinier-Preston zones and uniformly precipitated nanoscale η‘/Mg(CuZn)2 strengthening phases enhances both yield and ultimate tensile strength by >200%. By delivering high-performance products from scrap that are not just recycled but upcycled, this scalable manufacturing approach provides a model for metal reuse, with the option for on-demand upcycling of a variety of metallic materials from scrap sources.

Suggested Citation

  • Tianhao Wang & Xiao Li & Zehao Li & Tingkun Liu & Xiang Wang & Arun Devaraj & Cindy A. Powell & Jorge F. Santos, 2024. "Upcycled high-strength aluminum alloys from scrap through solid-phase alloying," Nature Communications, Nature, vol. 15(1), pages 1-8, December.
    • Handle: RePEc:nat:natcom:v:15:y:2024:i:1:d:10.1038_s41467-024-53062-2
    DOI: 10.1038/s41467-024-53062-2
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