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Science
25 December 2024

New Solid-Phase Processing Transforms Aluminum Scrap Into High-Strength Alloys

Innovative method raises the bar for aluminum recycling, achieving impressive material properties without melting.

A new solid-phase alloying method enables the upcycling of aluminum scrap, leading to the creation of high-strength aluminum alloys with properties similar to traditional high-performance alloys.

Researchers from Pacific Northwest National Laboratory (PNNL) have introduced a solid-phase recycling and simultaneous alloying method for upcycling aluminum scrap. This innovative technique is significant because it overcomes the limitations associated with traditional melt-based aluminum recycling processes, which have restricted alloy composition and properties.

The study was published recently (2024) and conducted at PNNL. The rationale behind this research stems from the substantial environmental impact of primary aluminum production, which is energy-intensive and generates significant greenhouse gas emissions. By utilizing 100% aluminum scrap, the researchers aim to drastically reduce energy and carbon emissions compared to conventional methods.

The method employs friction extrusion, allowing aluminum scrap to be processed with alloying elements such as copper, zinc, and magnesium without the need to melt the materials. This technique enables the production of high-performance aluminum alloys, which are expected to yield over 200% increase in yield and ultimate tensile strength compared to conventional recycled alloys.

According to the researchers, "By delivering high-performance products from scrap, this scalable manufacturing approach provides a model for metal reuse." This statement emphasizes the potential of the new upcycling process and its relevance to future sustainable manufacturing.

Friction extrusion not only optimizes the recycling process by reducing temperature and energy use but also leads to the homogeneous distribution of alloying elements within the aluminum matrix. The final upcycled aluminum products demonstrate properties akin to high-performance alloys like 7075 aluminum with significant improvements.

The mechanical properties of the upcycled aluminum showcase substantial advancements, highlighting the process's ability to refine aluminum scrap effectively. The findings from the research indicate significant benefits not only for production efficiency but also for future material design.

The study concludes with discussions around potential applications of this solid-phase upcycling process, including the creation of new aluminum alloys and composites, which can be manufactured without relying on primary aluminum sources. This process also serves as an example of how industries can convert low-strength and low-cost aluminum scrap materials to high-strength, high-value products.

Research and development along these lines are expected to play a pivotal role in reducing the environmental footprint of aluminum production, reinforcing the importance of sustainable practices and innovative recycling methods.

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