Processing and Properties of Recycled Aluminum Alloys

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The metallurgical industry is in the midst of a significant shift with the use of lightweight materials such as aluminum at the forefront of transportation design considerations to improve fuel economy. As manufacturers rush to adapt to stricter emissions standards, forecasters project double digit demand growth for aluminum automotive applications over the next decade. The use of recycled aluminum products in lightweight automotive vehicles results in energy savings of 95% compared to the use of products produced from primary aluminum and hence from an energy perspective there are huge incentives to using recycled aluminum products. ******The focus of my research continues to be the intersection between advanced lightweight metallic materials and manufacturing and ways to improve both manufacturability of these alloys but also the effect of manufacturing on their final mechanical properties. Within this realm, a key area that has received almost no attention is the impact of using recycled aluminum on the manufacturability and formability of aluminum alloys. The overall objective of this research is to develop scientific understanding of the impact of increased levels of specific elements (Fe, Mn, Cr and Cu), that can accumulate due to recycling, on the microstructure evolution during processing of AA6xxx aluminum products and their final properties. Currently almost no information exists on the role that element changes associated with recycling has on manufacturability and final alloy properties for wrought aluminum alloys. This research could ultimately be used to design manufacturing routes and products which help to mitigate any detrimental impacts as well as maximize any benefits when using recycled aluminum. ******Recycled aluminum is different from its primary parent sheet as there is an unavoidable accumulation of certain elements during recycling due to the manner in which the material is processed and prepared. These elements include iron (Fe), silicon (Si) and manganese (Mn) which are typically found in the primary metal, but can also include other elements such as copper (Cu) which is one of the alloying elements in several commercial alloys within the AA6xxx alloy family, as well as, vanadium (V), zinc (Zn), nickel (Ni), chromium (Cr) and lead (Pb) which may also enter into the aluminum processing stream. The starting composition of the aluminum directly affects the elements in solid solution as well as the particles that form in the aluminum matrix during casting and further processing. ******This research will provide a unique and valuable opportunity for research students to develop skills in materials manufacturing and characterization and understand the role that recycling can play in the reuse of materials. **