Friction-Induced Recycling Process for User-Specific Semi-Finished Product Production

Abstract

Modern forming processes often allow today the efficient production of complex parts. In order to increase the sustainability of forming processes it would be favorable if the forming of workpieces becomes possible using production waste. At the Chair of Forming and Machining Technology of the Paderborn University (LUF) research is presently conducted with the overall goal to produce workpieces directly from secondary aluminum (e.g., powder and chips). Therefore, friction-based forming processes like friction spinning (or cognate processes) are used due to their high efficiency. As a pre-step, the production of semi-finished parts was the subject of accorded research work at the LUF. Therefore, a friction-based hot extrusion process was used for the full recycling or rework of aluminum chips into profiles. Investigations of the recycled semi-finished products show that they are comparable to conventionally produced semi-finished products in terms of dimensional stability and shape accuracy. An analysis of the mechanical properties of hardness and tensile strength shows that a final product with good and homogeneously distributed properties can be produced. Furthermore, significant correlations to the friction spinning process could be found that are useful for the above-mentioned direct part production from secondary aluminum.

Analysis of temperature effect on strength and microstructure in friction induced recycling process (FIRP)

“…The profiles produced show significant grain refinement within the microstructure compared to reference wires. Also for this recycling process a reduction of energy input could be achieved compared to secondary aluminium production [16,17].…”

Assessment of Mechanical and Optical Properties of Al 6060 Alloy Particles by Removal of Contaminants

“…The friction‐induced recycling process, which is based on the conform process, [ 13 ] enables the continuous recycling of aluminum scrap through the continuous rotation of the wheel. [ 14 ] The feasability of the process for producing a semi‐finished product with good properties was demonstrated in initial basic investigations. In addition, the combined processing of different aluminum scrap with an energy saving of 50% compared to the conventional recycling process could be demonstrated.…”