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

Tianhao Wang, Xiao Li (), Zehao Li, Tingkun Liu, Xiang Wang, Arun Devaraj, Cindy A. Powell and Jorge F. Santos ()
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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

Nature Communications, 2024, vol. 15, issue 1, 1-8

Abstract: 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.

Date: 2024
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DOI: 10.1038/s41467-024-53062-2

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