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

Tianhao Wang; Xiao Li; Zehao Li; Tingkun Liu; Xiang Wang; Arun Devaraj; Cindy A Powell; Jorge F Dos Santos

doi:10.1038/s41467-024-53062-2

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

Nat Commun. 2024 Dec 10;15(1):10664. doi: 10.1038/s41467-024-53062-2.

Authors

Tianhao Wang¹, Xiao Li², Zehao Li¹, Tingkun Liu¹, Xiang Wang¹, Arun Devaraj¹, Cindy A Powell¹, Jorge F Dos Santos³

Affiliations

¹ Pacific Northwest National Laboratory, Richland, WA, USA.
² Pacific Northwest National Laboratory, Richland, WA, USA. xiao.li@pnnl.gov.
³ Pacific Northwest National Laboratory, Richland, WA, USA. jcpace911@gmail.com.

Abstract

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.