Abstract
The melt conditioned direct chill (MC-DC) casting process has been used to produce billets and extruded planks of AA5754 alloy formulated from 100% recycled Taint Tabor scrap aluminum. The billets were homogenized and then extruded into flat planks. Optical metallography of the MC-DC cast billets showed equiaxed refined grains in comparison to conventional direct chill (DC) cast and direct chill grain refined (DC-GR) cast billets formulated from the same Taint Tabor scrap. Microstructural evaluation of the extruded planks showed extensive peripheral coarse grain (PCG) for the DC, DC-GR and MC-DC cast planks. The 2 mm and 1 mm MC-DC cast planks produced after cold rolling and heat treatment showed a fully recrystallized microstructure at 380 °C and 300 °C for 10 min respectively with an improvement in mechanical properties over DC-GR cast and similarly processed planks. The as-extruded MC-DC cast planks tensile tested in the transverse direction showed 34% elongation and 213 MPa ultimate tensile strength. These tensile results showed 5.8% higher elongation and 1.2% higher ultimate tensile strength compared with the DC-GR planks after applying high shear melt conditioning.
Highlights
Research activities on recycling to save natural resources have been well supported and funded for the past few years
Higher elongation and 1.2% higher ultimate tensile strength compared with the direct chill (DC)-GR planks after applying high shear melt conditioning
The aim of this study was to investigate the impact of high shear melt conditioning (HSMC) on the microstructure and mechanical properties of the AA5754 alloy formulated from 100% Taint Tabor (TT) scrap aluminum processed into a flat bar after DC, direct chill grain refined (DC-GR) and melt conditioned direct chill (MC-DC) casting followed by subsequent thermomechanical treatment of extrusion and cold rolling
Summary
Research activities on recycling to save natural resources have been well supported and funded for the past few years. The main target of this research has been the extraction of metallic fractions from waste and scrap sources to facilitate its reuse in industrial applications. Recycling of Al-alloys has an economic and environmental benefit as the processing of secondary aluminum from recycled resources consumes 2.8 kWh/kg while the production of the primary Al requires about 45 kWh/kg of energy [1]. AA5754 is an important automotive body sheet alloy used for structural applications in the automotive industry because of its good formability. Due to its deep drawing characteristics, it is used in structural panels as an alternative to a mild steel sheet.
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