Sustainable recycling of aerospace-grade ultra-clean 7050 aluminum alloy melts through argon refining without secondary aluminum dross generation

Abstract

The refining of aluminum scraps commonly employs nitrogen-fluxes to eliminate impurities. However, the aluminum nitride (AlN) generated by the reaction between nitrogen and the aluminum melt, along with residual fluxes, contribute to low cleanliness of the recycled aluminum melt and pose difficulties for the disposal of secondary aluminum dross (SAD). Our innovative research has resulted in the recycling of aerospace-grade clean aluminum alloy melts. The results indicate that the argon bubble floating process adsorbs inclusions and hydrogen, achieving an aerospace-grade ultra-clean melt. The solid-liquid interface between the tube wall and the melt provides a diffusion channel for hydrogen atoms, and the bubbles rising up along the wall lead to a higher hydrogen content in the melt. The argon refining dross is primarily composed of Al and Al2O3, which can be recycled as a raw material for aluminum electrolysis. Argon refining can decrease the hydrogen content and the number of inclusions with particle size ≥40 μm in the recycled aluminum melt to the level of aerospace aluminum alloy melt. Nonetheless, the particle size ≥20 μm remains 1.5–2.5 times that of primary aluminum.