About this Abstract |
| Meeting |
2027 TMS Annual Meeting & Exhibition
|
| Symposium
|
Circular Metallurgy: Design, Technology, Application
|
| Presentation Title |
Production of Low-Fe Aluminum Alloys through Efficient Iron Removal from Casting Scrap |
| Author(s) |
Manish K. Sinha, Chuan Zhang, David Weiss, Subodh Das, Mathew Gavin, Tom Grosko, Samuel Wagstaff, Michael Pambianchi, Andrea Young, John Pickens, Bob Hubbard, Brajendra Mishra |
| On-Site Speaker (Planned) |
Manish K. Sinha |
| Abstract Scope |
Aluminum (Al) is a cornerstone of the circular economy because it can be recycled indefinitely without loss of intrinsic properties. Secondary Al production consumes up to 95% less energy than primary production and substantially reduces greenhouse gas emissions, highlighting the advantages of recycling as recycled scrap is projected to supply nearly 50% of Al in use by 2050. However, increasingly heterogeneous scrap streams introduce impurities, particularly Fe, along with Si, Cu, and Zn, which degrade mechanical properties, castability, processability, and recyclability. An efficient gravity sedimentation process was established to promote the nucleation and settling of Fe-rich intermetallic compounds prior to α-Al solidification, enabling effective Fe removal. The purified alloy was comprehensively characterized, and its microstructure and properties were compared with those of a commercial low-Fe alloy. A techno-economic analysis was conducted to assess industrial feasibility. The results demonstrate a practical pathway for upgrading secondary Al and advancing sustainable closed-loop recycling. |
| Proceedings Inclusion? |
Undecided |
| Keywords |
Other, Other, Other |