Weld strength in solid–state recycling of aluminum chips

Abstract

In solid‐state recycling, chip morphology related parameters such as size fraction, surface topography and geometry are important factors in resulting final bond strength. Analyzing deformation parameters together with chip morphology can provide an insight of which factors are very crucial to mechanical performance of the recycled chips. This work investigates the effect of chip morphology and in particular chip roughness and surface area on the weld strength of direct recycled aluminum chips. The influence of these factors were compared with the influences of temperature and pressure. Full factorial design with center point analysis was adopted to rank the factors effects. The chips of AA6061 were cold compacted at 10 tonnes and subsequently hot forged through the dog bone shape‐die at different operating regimes. The elastic and plastic behavior and ultimate tensile strength of the hot‐pressed samples were analyzed and compared. It was found that temperature and pressure are more important to be controlled rather than the chip morphology. Low chip roughness incorporated with high temperature revealed a very significant influence over the weld strength attainment. Regardless of the chip roughness, the bond strength can still be maximized when other deformation factors were controlled within the minimum specified limit.

Microstructure and fracture behavior of Al‐Si‐Mg alloy prepared with recycled alloy

“…A trend towards resource-efficient manufacturing can be observed in recent years driven by public concerns for environmental protection and resource conservation, but also as a result of the prospective stricter policies on climate change [1][2][3]. Non-ferrous metal recycling has a number of benefits, the most outstanding being the potential to reduce the extraction of virgin ores considerably, thus preserv-ing those non-renewable resources [4,5]. In terms of energy consumption, relying on the types of metals and the forms of scraps, recycling can save as much as a factor of 10 or 20 [6,7].…”

“…In terms of energy consumption, relying on the types of metals and the forms of scraps, recycling can save as much as a factor of 10 or 20 [6,7]. Today an increasing amount of the aluminium going into producing new aluminium alloy products is coming from recycled products [8,9]. Casting aluminumsilicon alloy has been widely used in industry and transportation for high strength, low density, excellent casting properties and many other advantages [10,11].…”

“…Casting aluminumsilicon alloy has been widely used in industry and transportation for high strength, low density, excellent casting properties and many other advantages [10,11]. The quality of recycled aluminumsilicon casting alloys is considered to be a key fac-tor in selecting an alloy casting for a particular engineering application [8].…”

Conjectured the Behaviour of a Recycled Metal Matrix Composite (MMC–AlR) Developed through Hot Press Forging by Means of 3D FEM Simulation

“…The improved solid state recycling process is a typical environmentally benign manufacturing process for aluminium alloys. Solid-state recycling, which involves direct recycling of metal scrap into bulk material using severe plastic deformation, has emerged as an alternative to conventional remelting and recycling techniques [ 1 , 2 , 3 ]. More waste generation was observed than from conventional recycling (melting), and it was also reported that primary aluminium is depleted and other resources should be utilized as alternative materials.…”

On the Role of Processing Parameters in Producing Recycled Aluminum AA6061 Based Metal Matrix Composite (MMC-AlR) Prepared Using Hot Press Forging (HPF) Process

“…Although metal recycling has many advantages, it has not been spared from environmental dispute. In recent years, many attempts have been made to create environmentally-friendly recycling technologies that are adaptable, reliable, energy saving, free from harmful substances, and reduce production waste and harmful emissions [ 4 , 5 ]. Direct conversion methods of recycling aluminum have many benefits, including cost and energy savings, and environmental protection by reducing the hazardous gas emissions compared to traditional recycling methods [ 1 ].…”