About this Abstract |
| Meeting |
2027 TMS Annual Meeting & Exhibition
|
| Symposium
|
Circular Metallurgy: Design, Technology, Application
|
| Presentation Title |
Suppressing Fe-Rich Intermetallics in High-Fe Recycled Aluminum via Cooling-Rate Engineering and Nucleation Modeling |
| Author(s) |
Kyaw Hla Saing Chak, Sammel M William, Koustav Dey, Sunyong Kwon, Jie Huang, Ying Yang, Yijia Gu |
| On-Site Speaker (Planned) |
Yijia Gu |
| Abstract Scope |
Recycling aluminum reduces energy use by up to 95% relative to primary production, but structural use of recycled Al is limited by elevated Fe, which promotes coarse, brittle Fe-rich intermetallic compounds (FeRICs) during solidification. This work presents a predictive strategy to suppress FeRIC formation in high-Fe recycled aluminum through cooling-rate engineering and nucleation modeling. Using wedge-mold casting with a high-fidelity fiber-optic temperature sensor, we quantify cooling-rate-dependent phase selection in Al alloys containing 2–3 wt% Fe. We show that FeRIC formation can be fully suppressed at high cooling rates (~500 K s⁻¹), in agreement with a phase-selection model predicting the critical cooling rate needed to bypass FeRIC nucleation. These results define processing windows for controlling deleterious intermetallics without costly alloy additions and are directly relevant to rapid-solidification processes such as die casting, welding, and additive manufacturing, enabling higher recycled content in structural aluminum. |
| Proceedings Inclusion? |
Undecided |
| Keywords |
Recycling and Secondary Recovery, Aluminum, Solidification |