Harnessing Recycled Aluminum for Enhanced Alloy Performance: Primary Intermetallic Phase Control through Rapid Solidification
Dr. Yijia Gu1, Assistant Professor
Co-PI(s): Jie Huang1, Ying Yang2
1: Missouri University of Science and Technology, Rolla, MO 65409
2: Oak Ridge National Laboratory, Oak Ridge, TN 37831
Recycling aluminum (Al) significantly reduces carbon emissions and cost, as it saves up to 95% of the energy required to produce new Al from raw minerals. Despite these environmental and economic benefits, the use of recycled Al in structural applications is limited, primarily due to high levels of iron (Fe) impurities. Excess Fe in Al alloys lead to the formation of large, brittle Fe-Rich Intermetallic Compounds (FeRICs) during casting, severely impairing mechanical properties (fatigue resistance, ductility, and toughness, etc.). While the addition of alloying elements and increasing cooling rates can mitigate the negative effects of excess Fe, the complex interplay between these modifications on FeRIC formation remains poorly understood. This research aims to develop a comprehensive understanding and predictive capability for controlling FeRIC formation in recycled Al alloys. By combining real-time high-temperature characterization techniques, and advanced materials modeling, the project will investigate the mechanisms governing the formation of FeRICs at the microscopic level.
The project will establish a research capability for alloy development at Missouri University of Science and Technology by integrating advanced in situ characterization techniques and state-of-the-art materials modeling. Understanding the impact of processing conditions on the FeRIC formation mechanism will lay the foundation for the discovery and design of new and improved Al alloys, while broadly impacting the community through the establishment of experimentally validated solidification models. Ultimately, these findings will help inform the design of high-performance recycled Al alloys, enhancing their usability in high-pressure die casting, welding, additive manufacturing, and other rapid industrial solidification processes, potentially increasing energy conservation and reducing carbon emissions.
This research was selected for funding by the Office of Basic Energy Sciences.
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