Solidification processing of scrap Al-alloys containing high levels of Fe

The accumulation of iron in molten aluminium is one of the main concerns for the recycling and casting industries because it leads to the formation of undesirable Fe-rich intermetallic compounds which are detrimental to mechanical properties. Many methods have been developed in the past to reduce the iron accumulated in molten aluminium scrap, but they all suffer from poor efficiency. Hence, a more efficient method is urgently needed to mitigate the negative effect of high iron levels in the melt, thereby avoiding downgrading secondary aluminium to low quality products or the dilution with expensive primary aluminium. This contribution provides a study of the Fe-rich intermetallic compounds developed in aluminium casting alloys with high levels of Fe as a function of melt processing conditions. Results show that the formation of the Fe-compounds is not only dependent on the cooling rate and holding time before solidification, but more on the initial melt treatment as it enhances the nucleation and growth of the Fe-phases. Elemental addition of Mn leads to the formation of large and compact intermetallic particles, but at slow rate. Physical melt treatment by intensive high shearing produces a much faster nucleation and results in a fine dispersion of smaller iron containing intermetallic particles. The latter could be used either to increase the tolerance to iron contamination or to facilitate the iron removal process, providing huge benefits for the recyclability of scrap aluminium alloys as it would allow the transformation of low-grade feedstock into a low cost and small carbon footprint material for high quality castings