Upcycling of Aerospace Aluminum Scrap

To achieve the energy savings (90%) and CO2 emissions reductions (96%) offered by secondary aluminum [1], and to overcome the issues associated with recycling of aerospace aluminum alloys, a new process for recycling AA7075 scrap directly into a high strength castable secondary alloy is demonstrated. The new process involves enhancing the castability of wrought aerospace aluminum scrap by alloy chemistry optimization and minor alloying additions to reduce the hot tearing susceptibility and to enhance the mechanical properties of the secondary alloy. The proposed approach provides defect-free castings with mechanical properties comparable to premium aluminum casting alloys but at considerable energy and cost savings.