Abstract
In this study, the response surface methodology (RSM) and desirability function (DF) were utilized to optimize the recycling conditions of aluminum (AA6061) chips, in the presence of particulate alumina (Al2O3), to obtain a metal matrix composite of recycled aluminum (MMC-AlR) using hot press forging processes. The effects of temperature (430–530 °C) and holding time (60–120 min) were investigated. The introduction of 2.0 wt. % of Al2O3 to the aluminum matrix was based on preliminary research and some pilot tests. This study employed the 2k factorial design of experiments that should satisfy the operating temperatures (T) of 430 °C and 530 °C with holding times (t) of 60 min and 120 min. The central composite design (CCD) was utilized for RSM with the axial and center point to evaluate the responses to the ultimate tensile strength (UTS), elongation to failure (ETF), and microhardness (MH). Based on RSM, with the desirability of 97.6%, the significant parameters T = 530 °C and t = 120 min were suggested to yield an optimized composite performance with UTS = 317.99 MPa, ETF = 20.45%, and MH = 86.656 HV. Three confirmation runs were performed based on the suggested optimum parameters, and the error revealed was less than 25%. The mathematical models suggested by RSM could adequately describe the MMC-AlR responses of the factors being investigated.
Highlights
Aluminum finds broad use in air, road, and sea transport, food and medicine, packaging, construction, and electronics and electrical power transmission
The array was calculated using Equation (1), and the actual values were practically chosen from the low and high ends of the parameter range. These results were used as the input for further analysis by the Design Expert 8.0 software (Minneapolis, MN, US)
Without performing any modification on the response, each source term was examined for the probability (“Prob > F”)
Summary
Aluminum finds broad use in air, road, and sea transport, food and medicine, packaging, construction, and electronics and electrical power transmission. Aluminum foundries contribute to 1% of the world’s total manmade greenhouse emissions [2]. This negative contribution to energy consumption and the pollution caused to produce primary aluminum have made aluminum recycling, which is more economical and efficient, even more significant. Considering the high responsibility toward the environment, secondary aluminum production through a solid-state approach is a much more preferable process. In this approach, the aluminum is recycled without remelting the scrap, for the purposes of improving the recycling efficiency, energy use, and expense
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