Enhancing the properties of a hypereutectic Al-Fe alloy through recycled aluminum scrap and ultrasonic melt processing

This paper focuses on the effects of using recycled aluminum beverage cans and ultrasonic melt processing (USP) on the microstructure and properties of a hypereutectic Al-Fe alloy that has potential in structural and electric applications. The proportion of recycled aluminum scrap used as the starting material varied, and its influence on grain refinement, intermetallic phase formation, precipitation hardening, and mechanical performance was examined. Ultrasonic melt processing (USP) was applied to refine the microstructure and improve phase distribution. The experimental results showed that both the addition of recycled aluminum scrap and USP significantly increased the hardness and tensile strength of the alloys, with further improvements observed after optimal aging treatments, although ductility slightly decreased. Additionally, the presence of alloying elements from the recycled scrap, such as Mg, Mn, Si, and Cu, led to a reduction in electrical conductivity while improving the precipitation hardening response. This study highlights the potential of using recycled materials and advanced processing techniques to develop sustainable, high-performance aluminum alloys for various industrial applications.