Recycled Aluminum Research Articles

Double-edged effects of aluminosilicates formation on denitrification and desalination during the leaching process of secondary aluminum dross (SAD)

As the proportion of recycled aluminum increased, the production of secondary aluminum dross (SAD) increased dramatically, putting enormous pressure on the enterprises and environment. The utilization rate of SAD was less than 30 % due to problems such as high discharge of acidic/alkaline wastewater or restrictions on the salt content of raw materials. In a previous study, authors achieved self-driven hydrolysis of SAD by water leaching. However, the removal of Na and K was incomplete, which was also found in alkaline leaching processes and was more serious. To further identify the causes, the transformation behaviors of Al, Si, N, F, Cl, Na, and K in SAD during the water leaching process were investigated in this study. In addition, the double-edged effects of aluminosilicates formation on denitrification and desalination during the leaching process of SAD were also revealed. The results showed that the generation of Al(OH)3 inclusions during the hydrolysis of AlN inhibited the deep denitrification, while NH3 provided an alkaline driving force for the dissolution of Al(OH)3 and Si/SiO2. Dissociated Al(OH)4- and H3SiO4- reacted with Na+/K+ to form aluminosilicates, which promoted denitrification but inhibited desalination. Eventually, after 480 min of water leaching (L/S = 1.5, T = 80 °C), the denitrification was 86.39 %, the removal rate of Cl was 99.61 %, and the contents of Na and K in leaching residues were 0.39 wt% and 0.24 wt%, respectively. The leaching residues with an Al content of 37.41 wt% showed no leaching toxicity, which reached Grade I bauxite grade.

Role of the MnCoGe alloys to enhance the capacitance of flexible supercapacitors made with electrodes of recycled aluminum and carbon nanotubes

Flexible and sustainable supercapacitors (SCs) were fabricated with carbon nanotubes (CNTs) as the anode and recycled aluminium as the cathode (obtained from soda cans). Devices made with the configuration of CNT//Al had maximum energy-densities/capacitances of 97.8 Wh kg−1/313.5 F g−1. Later, MnCoGe (MCG) alloy powders doped with boron (MCG:B) or gallium (MCG:Ga) were incorporated into the SC electrodes and the energy-density/capacitance was enhanced up to 269.5 Wh kg−1/862.3 F g−1. This outstanding increment of the electrochemical performance was caused by the formation of multiple redox centers on the SC electrodes (oxygen vacancies, Mn3+/Mn4+, Co2+/Co3+, and Ge4+/Ge2+/Ge0) as confirmed by XPS and Raman spectroscopies. The SCs made with MCG alloys were immersed in acid (pH=3)/basic (pH=11) aqueous media and electrochemically tested. Surprisingly, the capacitance retention was reduced a maximum of 0.6%, demonstrating their capacity to operate underwater. The tests of bending and charging/discharging cycles demonstrated that the SCs made with the MCG:B powder were the most stable because their capacitance retention was above 95%. In contrast, SCs made with the MCG:Ga alloy had capacitance retentions below 93% after the same tests. Overall, we demonstrated that efficient/flexible/waterproof SCs can be made with low-cost aluminium, which of interest for wearable electronics.

Processing Techniques and Metallurgical Perspectives and Their Potential Correlation in Aluminum Bottle Manufacturing for Sustainable Packaging Solutions

This study explores the potential of aluminum wine bottles as a sustainable alternative to traditional glass bottles, emphasizing their recyclability and environmental advantages. It reviews the potential use of Al-Mn-Mg 3xxx alloys in beverage can bodies and examines various applications of aluminum containers in packaging, including recyclable beverage containers. The manufacturing processes for aluminum bottles, including casting, rolling, punching, and deformation techniques, are discussed in detail, with a particular focus on their impact on mechanical properties and microstructure. The preference for 1xxx aluminum alloys in impact extrusion is explained, highlighting their lower flow stress and higher formability compared to 3xxx alloys, and the microstructural changes induced by various processing steps are analyzed. Challenges related to using recycled aluminum and their effects on mechanical properties and microstructure during aluminum bottle production are also addressed. One objective is to increase the proportion of recycled alloyed material used in aluminum bottle manufacturing. Depending on the technique employed, the fraction of alloyed recycled material can vary. The percentage of recycled alloyed material (3xxx series Al alloys) in cold backward impact extrusion could be raised by 60%. High-speed blow forming could facilitate the production of aluminum bottles with a recycled alloyed material ranging from 50 to 100% of the 3xxx series aluminum can body alloys. The high-speed drawing and ironing (DWI) process can produce large-format aluminum bottles (up to 750 mL), utilizing at least 90% of the recycled 3xxx series can body stock. Furthermore, the paper discusses the importance of optimized heat treatment designs in enhancing mechanical properties and controlling microstructural evolution in alloyed aluminum materials, such as 3xxx series alloys. The study concludes with a need for further research to deepen our understanding of the metallurgical aspects of aluminum bottle manufacturing and to optimize the use of recycled aluminum in packaging solutions, with a specific focus on improving mechanical properties and microstructural integrity. This comprehensive review aims to contribute to the development of more sustainable packaging practices in the beverage industry by providing insights into the interplay between manufacturing processes, mechanical properties, and microstructure of aluminum bottles.

Optimizing the Design Structure of Recycled Aluminum Pressing Machine using the Finite Element Method

Optimizing the Design Structure of Recycled Aluminum Pressing Machine using the Finite Element Method

Influence of Alumina, Ferric Oxide, and Mn as Composites on the Properties of Recycled Aluminium Alloy

Recycling of aluminium alloys is gaining significant attention due to its economic and environmental benefits. However, close loop recycled aluminium alloys can be adversely affected by impurities and alloying elements present in the recycled feedstock. In this study, the influence of three composites, namely alumina (Al2O3), ferric oxide (Fe2O3), and manganese (Mn), on the properties of recycled aluminium taldon scraps was investigated to enhance the tensile behaviour of the alloys. The effects of these composites on the mechanical properties, microstructure, and corrosion behaviour of the recycled aluminium alloys were evaluated through experimental characterization techniques. The results showed that the addition of these composites had a significant influence on the properties of recycled aluminium alloys, providing insights into the potential for improving the performance of recycled aluminium alloys through composite additions. The addition of Al2O3 enhanced the tensile strength by 44.18 % and the variation can be attributed to the strengthening of the dendritic zones by the formation of α-Al.

LCA of recycling aluminium incineration bottom ash, dross and shavings in a rotary furnace and environmental benefits of salt-slag valorisation

Recycling aluminium in a rotary furnace with salt-fluxes allows recovering valuable alloys from hard-to-recycle waste/side-streams such as packaging, dross and incinerator bottom ash. However, this recycling route generates large amounts of salt-slag/salt-cake hazardous wastes which can pose critical environmental risks if landfilled. To tackle this issue, the metallurgical industry has developed processes to valorise the salt-slag residues into recyclable salts and aluminium concentrates, while producing by-products such as ammonium sulphate and non-metallic compounds (NMCs), with applications in the construction or chemical industries. This study aims to assess through LCA the environmental impacts of recycling aluminium in rotary furnaces for both salt-slag management routes: valorisation or landfill. It was found that this recycling process brings forth considerable net environmental profits, which increase for all the considered impact categories if the salt-slag is valorised. The main benefits arise from the production of secondary cast aluminium alloys, which is not unexpected due to the high energy intensity of aluminium primary production. However, the LCA results also identify other hotspots which play a significant role, and which should be considered for the optimisation of the process based on its environmental performance, such as the production of by-products, the consumption of energy/fuels and the avoidance of landfilling waste. Additionally, the assessment shows that the indicators for mineral resource scarcity, human carcinogenic toxicity and terrestrial ecotoxicity are particularly benefited by the salt-slag valorisation. Finally, a sensitivity analysis illustrates the criticality of the metal yield assumptions when calculating the global warming potential of aluminium recycling routes.

Effects of Fe content on the 3D morphology of Fe-rich phases and mechanical properties of cast Al-Mg-Si alloy

Fe is a common impurity element in recycled aluminum scraps, and adjusting Fe content can effectively promote the effective utilization of recycled aluminum. In this study, Al-Mg-Si-Mn-Fe alloys with different Fe contents were prepared by adding various percentage of aluminum scraps. Synchrotron X-ray tomography technology was used to study the morphological evolution of Fe-rich phases and corresponding effect on mechanical properties of studied alloys. The results showed that as the Fe content increased, the 3D morphology of Fe-rich phases changed from fine Chinese-script and needle-like shapes to coarse Chinese-script structure. Their 3D morphology was mainly composed of thin platelets and curved branches. The increase in Fe content did not significantly change the 3D structure of Fe-rich phases, but increased the volume fraction of large Fe-rich phases. When the Fe content reached 0.35 %, the maximum volume and the number of branches of individual phases increased by 182.9 % and 142.2 %, respectively, compared with the 0.2Fe alloy. With the increase of Fe content, the ductility of alloys gradually decreased, especially when the Fe content exceeded 0.25 %. The Fe content had a small effect on the liquidus temperature of alloys, but it changed the initial formation temperature and type of Fe-rich phases. When the Fe content exceeded 0.32 %, it promoted the formation of β-Fe phase, which may be the main reason for the significant decrease in ductility of studied alloys with higher Fe content.

An Innovative Approach to Assess the Potentiality of Using Activated Carbon and Rice Husk Ash in Aluminum-Air Battery

Aluminum-air (Al-air) cells have the potential to become vital in energy storage applications in the future because of their high energy density, which is even higher than that of commonly used lithium-ion batteries. However, it is not used widely because the cost of air cathode catalysts and metal anode is high. However, suppose the catalysts are replaced with activated carbon or rice husk ash as an alternative and recycled aluminum foil as an anode. In that case, the production cost might be feasible for the vast use of this type of cell. This study's main objective is to utilize some commonly available material in fabricating an Al-air battery suitable for small and day-to-day usage, reducing production costs and limitations. In this paper, a focused analysis was made on the feasibility of using an activated carbon and rice husk mixture as an air cathode catalyst for an Al-air cell, and the observations were interesting. About 11 samples of a mixture of rice husk ash (RHA) and activated carbon (AC) in different ratios have been made to find the best results from 0.68-0.72 V, which increases by 8-20%, measuring each sample after 3 days. In this study, another attempt was made to replace the graphite cathode of a dry cell with a mixture of AC and RHA. Voltage drop is quite negligible for the mixture of 10% RHA. The resulting voltage is similar to the new 100% activated carbon battery as a cathode. If considering the environmental effect, using recycled activated carbon and rice husk ash will decrease pollution and open a new door to apply in primary cells.

Study on Preparation Technology and Heat Conduction Mechanism of High-Purity & Ultra-Fine Alumina Powder from Scrap Aluminum Cans

In view of the increasing scarcity of bauxite resources in China, the high energy consumption and high pollution of electrolytic aluminum, and the requirements for energy conservation and environmental protection, aluminum recycling and high-value utilization of its derivatives have evolved into a crucial development requirement for the aluminum industry in the future. As an important part of the development of recycled aluminum resources, the high-value application of scrap aluminum cans has always been a hot research topic in various recycled aluminum processing enterprises and scientific research units. The traditional regeneration system of waste cans includes a series of complex technological processes such as pretreatment, paint removal, smelting system and casting system, which is difficult to control in the middle of the process. Most of the recycled scrap aluminum cans are cast and downgraded for later use, except for a part of them used as alloy materials for new cans. In this paper, combined with the research on the preparation of metal aluminum alkoxide, combined with recrystallization heat conduction to further study the effective dissolution or adsorption how to remove impurity elements to obtain high-purity aluminum alcohol salt mechanism research, and thermal effect of alcohols with different carbon chains on the synthesis of high-purity aluminum alkoxide was further investigated. Moreover, the changes in morphology and pore size distribution of hydrolyzed alumina precursor materials under different hydrothermal temperature conditions were discussed by means of the alkoxide hydrolysis-sol-gel process. Eventually, the aluminum alkoxide was obtained by the reaction of waste cans with isopropanol and heavy crystal thermal conductivity, and the high-purity aluminum alkoxide was purified by vacuum distillation. Under the hydrothermal condition of 160°C, the high-purity alumina material with a purity of 99.99% and an original crystal size of 200nm was prepared.

The Impact of Heating Temperature and Flux Ratio on the In-Situ Casting Technique as a Direct Recycling of AlSi7Mg Machining Chips

Recycling aluminium and its alloys is gaining popularity in reducing energy consumption and associated manufacturing expenses. The fluxing process is the preferred and often-used technique in the recycling sector for removing oxide inclusions from molten aluminium. The present study investigates the influence of flux ratio and heating temperature on the behaviour of aluminium alloy chips (AlSi7Mg) during in-situ casting. The primary objective is to create a more efficient and economical approach to recycling aluminium waste. The chips underwent heating for 30 minutes inside a controlled laboratory furnace. The temperatures used during this procedure were 750°C and 800°C. The chips were combined with flux in ratios of 1:0.1 and 1:0.2. The number of melted chips rose due to increasing the temperature and flux ratio. The heated samples were subjected to surface morphology and elemental analysis using a scanning electron microscope with energy-dispersive spectroscopy (EDS). The Energy Dispersive Spectroscopy (EDS) examination indicated the presence of oxygen on the surface of the unprocessed aluminium alloy machining chips. On the other hand, the X-ray diffraction (XRD) revealed that the observed condition may be attributed to the oxidation process, proven by the presence of Aluminium Oxide (Al2O3).

CFD simulation and water model experiments with overflow-type supergravity reactor set up for continuously removing inclusions from aluminum melt

In this work, an overflow-type supergravity reactor has been tested for removal of inclusions from aluminum melt. A combination of numerical and physical simulations was employed to investigate the continuous separation process of recycled aluminum melt and inclusions, with a focus on evaluating the effects of reactor structures, process parameters, and inclusion characteristics on the inclusion separation efficiency. The results of numerical simulation indicate that the inclusion separation efficiency is positively related to overflow pipe length (L), overflow pipe installation height (H), gravity coefficient (G), inclusion density (ρ) and inclusion diameter (d), and negatively related to overflow pipe diameter (Φ) and melt inflow rate (Q). The overflow-type supergravity reactor exhibited excellent performance in separating inclusions from recycled aluminum melt. Under the conditions of L = 40 mm, H = 108 mm, Φ = 10 mm, G = 500, and Q = 0.5 kg/s, the separation efficiency of 18 μm Al2O3 inclusions reached nearly 100 %. The high consistency between the results of numerical and physical simulations provided full verification of the reliability and accuracy of the numerical simulation.

Life cycle assessment of direct recycling hot press forging of aluminium AA7075 metal matrix composite

The primary objective of this research is to investigate the process of direct recycling of AA7075 aluminium alloy, which is extensively utilised in the aerospace and flight sectors due to its exceptional strength and lightweight characteristics. Alumina (Al2O3) is used as a reinforcing agent and the effect of hot press forging (HPF) parameters on the mechanical characteristics and surface integrity of the metal matrix composite (MMC) constructed of AA7075 alloy with 1% Al2O3 has been studied. Furthermore, the utilisation of an integrated life cycle assessment (LCA) approach is implemented to assess the environmental impacts and economic expenses associated with the recycling of aluminium via high-pressure forming for both the metal matrix composite and AA7075 alloy. Response surface methodology (RSM) is applied to ascertain the optimal parameters for high-performance filtration. The findings suggest that employing a forging temperature of 532.34 °C and a holding time of 60 min produces favourable results. When comparing the characteristics of the MMC and recycled aluminium, it can be observed that they both demonstrate similar essential process attributes. The utilisation of HPF in conjunction with the Multi-Material Composite has the potential to yield a reduction of up to 24.97% in Global Warming Potential (GWP). This research demonstrates the efficacy of HPF as a viable approach for environmentally conscious and economically efficient recycling of AA7075 aluminium scrap, thereby improving product performance and promoting sustainability.

Characterization and Utilization of Recycled Aluminium Residues for Eco-Friendly Road Construction Practices

Characterization and Utilization of Recycled Aluminium Residues for Eco-Friendly Road Construction Practices

Mechanical Properties Response of Heat Treated Recycled Aluminium Alloy Reinforced with Gold Nanoparticle (AuNps) Extracted from Aloe Vera Leaf

Aluminium and its alloys are becoming more widely used in engineering due to a growing need for lightweight metals. However, owing to boundary segregation and coarse dendritic grains, typical cast aluminium alloys have low hardness and strength, limiting their use in large-scale and complex-shaped applications. Many studies have shown that reinforcing aluminium alloy with nanoparticles synthesized by various chemical and physical ways improves these shortcomings, but these approaches are both expensive and potentially dangerous. Recycling aluminium scrap is also necessary to save energy and money. Therefore, this research aimed at production of high tensile strength and hardness from scrapped aluminium reinforced with synthetic nano particle and subjected to heat treatment. The elemental composition of aluminium alloy cast from scrap was analyzed using a Light Emission Polyvac Spectrometer, and gold nanoparticles were synthesized from aloe vera leaves. In creating a Metal Matrix Nano Composite, Al alloy was reinforced with gold nanoparticles at various percentages. At 450 °C, the reinforced Metal Matrix Nano Composite was hardened. The composites' hardness, tensile strength, and microstructural analyses were determined. The composites' grain structure demonstrated a uniform distribution of reinforcing phase of Al 6063 Alloy. The microhardness and tensile strength of the composites are influenced by the % weight proportion of AuNps and the heat treatment. After 3 percent and 6 percent weight of AuNps reinforcement were used, the microhardness/tensile strength of the reinforced sample rose by 22.4 Hv/58MPa and 24.7 Hv/80MPa, respectively, but when the composites were hardened, it climbed to 41 Hv/109 MPa and 45.5 Hv/125 MPa. After 3 percent and 6 percent weight of AuNps reinforcement were used, the microhardness/tensile strength of the reinforced sample rose by 22.4 Hv/58MPa and 24.7 Hv/80MPa, respectively, but when the composites were hardened, it climbed to 41 Hv/109 MPa and 45.5 Hv/125 MPa.

Recycling of beryllium swarf for the preparation of Be/Al composites with high mechanical properties by pressure infiltration method

Utilizing recycled beryllium swarf and aluminum, Be/Al composites containing varying volume fractions of beryllium were fabricated via the pressure infiltration method, which realized the direct and green recycling of beryllium swarf without dust. This study systematically investigates the microstructure and mechanical properties of Be/Al composites. Under pressure infiltration conditions, the molten aluminum successfully repaired the defects in the beryllium swarf. Additionally, the serrated morphology of the swarf increased the contact area between the beryllium swarf and aluminum matrix, enhancing interfacial bonding strength. As the volume fraction of beryllium swarf increased, the tensile strength, yield strength, and elastic modulus of the composite material increased, while elongation exhibited a different trend. Considering the service conditions of the material, 60% volume fraction is the optimal parameter. The fracture of Be/Al composites comprised both ductile fracture of the Al phase and brittle fracture of the Be phase. The debonded surface of beryllium swarf reinforcement was generally smooth rather than densely cracked or large serrated.

Superior hydrogen production rate by corrosion of recycled aluminum alloys: Feeding a PEM fuel cell

Aluminum is one of the most versatile materials for the dynamic global economy due to its mechanical properties, recyclability, and lightweight. The production of hydrogen from aluminum via hydrolysis in alkaline media offers another advantage of it. Recycling the post-consumer aluminum scraps leads to the formation of some undesirable intermetallic particles which are not only detrimental to mechanical properties but also to repeated recycling. In this study, the hydrolysis performance of a recycled aluminum alloy was compared with that of the primarily produced one. The results showed that the Mg solutes at the grain boundaries (GBs), Fe-containing and Mg2Si particles, stress concentration around the GBs, and thickness of the passive layer can affect the hydrogen generation rate of the specimens. The specimens were also tested in a proton-exchange membrane fuel cell to evaluate their hydrogen generation performance. The recycled aluminum alloy that can increase the hydrogen yield significantly increases the power of PEMFC.

An experimental investigation of the thermal performance of solar collectors utilizing finned aluminum can pipes

An innovative experimental study is presented to improve the performance of solar collectors designed for solar drying systems, focusing on the use of recycled aluminum can waste and the development of the air solar collector. The latter’s absorber is made up of 10 cans with a diameter of 65 mm, a length of 160 mm and a thickness of 0.3 mm, forming a cylindrical finned pipe. Several collector configurations under identical weather conditions, including four collectors with different rows of rods (4, 8, 12–14 rows) and a single collector, were analyzed and compared. The thermal performance of this new collector model was assessed on the basis of solar fluxes and collector inlet and outlet temperatures, collected during the month of September 2021. Experimental results revealed that this collector can increase the outlet temperature of air from 32°C up to 130°C, in the case of a 14-row collector. The study also showed that, at low flow rates, the can-equipped collector achieves an efficiency of 54% for the case of a 14-row collector, compared with 34% for the simple case, representing a 20% improvement over the single case. The study also showed that, at low flow rates, the can-equipped collector achieves higher outlet temperatures.

Corrosion Behaviour of Recycled Aluminium AlSi9Cu3(Fe) Machining Chips by Hot Extrusion and Thixoforming

The corrosion properties of an EN AC AlSi9Cu3(Fe) alloy (reference sample (RS)) and samples produced by recycling chips of RS by direct hot extrusion (DHES) and subsequent thixoforming (TFS) were tested in 0.5 M NaCl solution. The plastic deformation changes the microstructure of RS, and brittle, coarse Si particles and intermetallic compounds (IMCs) were effectively broken into ultrafine-grained particles and redistributed homogeneously into the α-Al matrix in DHES. TFS exhibits a globular structure, and polyhedral clusters rich in Si and IMCs were observed along the grain boundary. Electrochemical measurements combined with surface characterisation show that the microstructure significantly influences the tested samples’ corrosive properties. It was confirmed that corrosion resistance increased in the following order: RS < TFS < DHES. Similarly, the corrosion potential becomes nobler, the corrosion current decreases, the passive area increases, and the oxide layer becomes more stable (higher resistance and thickness). Also, the percentage of the surface affected by corrosion and the volume of pits reduce. The effect of microstructure is particularly pronounced in the level of the corrosion current and the volume of pits formed. The corrosion current of DHES and TFS decreases by 4–5 times, while the pit volume of DHES and TFS decreases by several orders of magnitude compared to RS. The corrosion stability of DHES and TFS in relation to RS is a consequence of the comminution of the Si particles and the IMC. The refined and homogeneous microstructure contributes positively to forming a stable oxide film on DHES and TFS and increases their corrosion resistance in an aggressive environment. The applied recycling method represents an innovative and sustainable process for the recycling of semisolid materials, with lower energy consumption and less greenhouse gas emissions compared to conventional recycling. The fact that the products obtained through recycling have a significantly higher corrosion resistance further increases the economic and environmental impact of the process.

A Circular Economy? Aluminum Recycling in Historical Perspective

Cet article se concentre sur l’histoire du recyclage de l’aluminium, entre la hausse de sa production lors de la Deuxième Guerre mondiale et le début du XXI e siècle, pour évaluer les affirmations selon lesquelles le recyclage de l’aluminium constituerait une économie circulaire. Ces affirmations reposent sur des taux contemporains élevés de valorisation et de recyclage, et s’appuient sur l’histoire de la récupération des métaux secondaires, notamment avec l’augmentation des systèmes de collecte publics associés à une perception du recyclage en tant qu’activité écologique. À partir du travail de spécialistes en « Discard studies » (études des déchets) comme Samantha MacBride et Josh Lepawsky, le présent article étudie dans quelle mesure ces affirmations représentent, ou non, des efforts significatifs pour réduire les dommages environnementaux causés par la production initiale d’aluminium. La multiplication des programmes de collecte publics a participé à l’essor du recyclage au cours du dernier demi-siècle. L’utilisation plus fréquente de l’inclusion du métal dans les emballages, pour la conception industrielle et pour d’autres applications a toutefois intensifié la production initiale qui a plus que triplé à l’échelle mondiale sur cette période. Cet article conclut par un débat sur les limites du recyclage et les stratégies susceptibles de réduire la production primaire.

Design of aluminum eco-composite for sustainable engineering application by the valorization of municipal wastes: Experimental and response surface analysis

Reprocessing municipal wastes into useful engineering components is one way to reduce their environmental impact. This paper presents a report on an alternative experimental approach to reprocessing common environmental wastes like aluminum scraps, steel shavings, and coconut shells into eco-friendly engineering composite. Equally, response surface analysis was incorporated in the development and validation of predictive models fit for future prediction of response properties. Aluminum scrap was heated into a liquid state and reinforced with recycled steel particles (RSP) and coconut shell ash particles (CSP) at varying proportions. Specimen design involves three group mixes: A, B, and C. Each of the three groups mixes comprised 0, 1, and 2 % RSP at constant dosage, respectively. Meanwhile, each mix was incorporated with 4, 8, and 12 wt % CSP. The microstructural features, physical (porosity, density, and relative density), and mechanical (tensile strength, hardness, elastic modulus, fracture toughness, impact strength, and percentage ductility) properties were appraised. The outcome revealed that the combination of the two reinforcements (RSP and CSP) contributed to microstructural evolution within the specimens. The porosities of the composite specimens were reported to marginally increase with the reinforcement combination. Interestingly, the composite exhibited lighter weight with improved mechanical performance. Mathematical models derived for the response properties were certified fit for future analysis and predictions. Meanwhile, the optimization procedure revealed that the combination of 1.3 % RSP and 6.7 % CSP was suitable for the design of optimal recycled aluminum composites for sustainable engineering designs. The results clarified that the reinforcement particles (RSP and CSP) are low-cost alternatives to synthetic ceramic reinforcements in the aluminum composite."