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DOE OSTI · 2561387

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

Wang, Tianhao [Pacific Northwest National Laboratory (PNNL), Richland, WA (United States)] (ORCID:0000000271512658)·Li, Xiao [Pacific Northwest National Laboratory (PNNL), Richland, WA (United States)] (ORCID:000000032096298X)·Li, Zehao [Pacific Northwest National Laboratory (PNNL), Richland, WA (United States)] (ORCID:0000000238671462)·Liu, Tingkun [Pacific Northwest National Laboratory (PNNL), Richland, WA (United States)] (ORCID:0000000345645462)·Wang, Xiang [Pacific Northwest National Laboratory (PNNL), Richland, WA (United States)] (ORCID:0000000296293084)·Devaraj, Arun [Pacific Northwest National Laboratory (PNNL), Richland, WA (United States)] (ORCID:0000000313146212)·Powell, Cynthia (Cindy) A. [Pacific Northwest National Laboratory (PNNL), Richland, WA (United States)] (ORCID:0009000195990101)·dos Santos, Jorge Fernandez [Pacific Northwest National Laboratory (PNNL), Richland, WA (United States)] (ORCID:0000000342894957)
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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.

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36 MATERIALS SCIENCEaluminumrecyclingsolid phase processingupcycling

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Wang, Tianhao [Pacific Northwest National Laboratory (PNNL), Richland, WA (United States)] (ORCID:0000000271512658), Li, Xiao [Pacific Northwest National Laboratory (PNNL), Richland, WA (United States)] (ORCID:000000032096298X), Li, Zehao [Pacific Northwest National Laboratory (PNNL), Richland, WA (United States)] (ORCID:0000000238671462), Liu, Tingkun [Pacific Northwest National Laboratory (PNNL), Richland, WA (United States)] (ORCID:0000000345645462), Wang, Xiang [Pacific Northwest National Laboratory (PNNL), Richland, WA (United States)] (ORCID:0000000296293084), Devaraj, Arun [Pacific Northwest National Laboratory (PNNL), Richland, WA (United States)] (ORCID:0000000313146212), Powell, Cynthia (Cindy) A. [Pacific Northwest National Laboratory (PNNL), Richland, WA (United States)] (ORCID:0009000195990101), dos Santos, Jorge Fernandez [Pacific Northwest National Laboratory (PNNL), Richland, WA (United States)] (ORCID:0000000342894957). 2024-12-10. Upcycled high-strength aluminum alloys from scrap through solid-phase alloying. https://doi.org/10.1038/s41467-024-53062-2

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