Phase Evolution of ß–Al5FeSi during Recycling Al–Si–Fe Alloys by Mg Melt

"The recycling of aluminum materials is a green industry while Al–Si–Fe is a typical scrap aluminum alloy. The key point of recycling Al–Si–Fe alloys is to separate Al and Fe. A method by introducing Al–Si–Fe alloy into Mg melt has been investigated in this work. A separation layer with gathered Fe–rich and Al–poor Fe3Al0.7Si0.3particleswereobtained at the bottom of the cooled ingot, indicating that ß–Al5FeSi phase evolves to Fe3Al0.7Si0.3,and quantities of Al are released to the upper Mg matrix simultaneously. However, the evolution of Al3Fe by adding binary Al–Fe alloy into Mg melt is different. It is supposed that element Si plays an important role in the phase evolution procedure, thus affects the performance of this method.INTRODUCTIONThe rapid development of aeronautic, automotive and aerospace technologies strongly depends on the consumption of materials while sustainable development is the future direction. Aluminum is a recyclable material and Fe is one of the most common impurities. Fe can be introduced into Al alloys by adding low–purity alloying materials and by using unprotected ferrous crucible, tools, or equipment (Belov, Eskin, & Avxentieva, 2005; Lu& Dahle, 2005).For instance, wear–resistant rings are usually inserted into piston head when producing Al–Si pistons and an infiltration procedure by putting the cast iron rings into Al melt before casting is always essential. As a result, both the re–melting of pistons and the reuse of Al melt for infiltrating rings lead to the enrichment of Fe element, which can be even high to5 wt.%(Viala, Peronnet, Barbeau, Bosselet, & Bouix, 2002).It is widely known that coarse ß–Al5FeSi particles will form in high Fe–contained Al–Si–Fe alloys which is harmful for the mechanical properties. In the past decades, several methods to eliminate the harmful effect of ß–Al5FeSi have been investigated which can be widely referred (Munson, 1967; Lee, Kawamura, Inoue, Cho, & Masumoto, 1997; Suárez–Peña& Asensio–Lozano, 2006; Eidhed, 2008).These methods can be divided into two kinds. One is to aggregate and remove the Fe–rich phase through the methods of centrifugation, gravity filtration or magnetic separation. The other way is modifing the morphology of flake–like ß–Al5FeSi by overheating the melt or adding neutralized elements. However, these traditional methods are rarely used due to respective disadvantages, while the commonly used method in industries is using primary aluminum for dilution. However, only less than 30wt.% of scrap Al can be added into primary Al melt for each melting work while it also results in the decrease of product quality simultaneously(Zhang, Liu, & Liu, 2016)."