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

Wang, Tianhao; Li, Xiao; Li, Zehao; Liu, Tingkun; Wang, Xiang; Devaraj, Arun; Powell, Cynthia (Cindy) A.; dos Santos, Jorge Fernandez

doi:10.1038/s41467-024-53062-2

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

Journal Article · Mon Dec 09 19:00:00 EST 2024 · Nature Communications

DOI: https://doi.org/10.1038/s41467-024-53062-2 · OSTI ID:2561387

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Pacific Northwest National Laboratory (PNNL), Richland, WA (United States)

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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Research Organization:: Pacific Northwest National Laboratory (PNNL), Richland, WA (United States)

Sponsoring Organization:: USDOE Laboratory Directed Research and Development (LDRD) Program

Grant/Contract Number:: AC05-76RL01830

OSTI ID:: 2561387

Report Number(s):: PNNL-SA--196125

Journal Information:: Nature Communications, Journal Name: Nature Communications Journal Issue: 1 Vol. 15; ISSN 2041-1723

Publisher:: Nature Publishing GroupCopyright Statement

Country of Publication:: United States

Language:: English

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

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