Published in Nature Communications, the study demonstrates transforming scrap aluminum into high-performance alloys without conventional melting processes.
The upcycled aluminum performs as well as primary aluminum.
The process provides a low-cost pathway for high-quality recycled metal products, contributing to environmental sustainability.
Solid Phase Alloying:
Converts aluminum scrap mixed with copper, zinc, and magnesium into high-strength alloys in minutes.
This method bypasses the need for melting, casting, and extrusion, which typically take days.
Utilizes a patented technique, Shear Assisted Processing and Extrusion (ShAPE), to uniformly disperse ingredients via friction and heat.
Produces high-strength alloys with characteristics matching newly manufactured aluminum products.
Eliminates energy-intensive bulk melting, significantly reducing manufacturing costs.
Low-cost scrap feedstocks contribute to affordable production of durable, high-performance recycled materials.
Applications for Recycled Aluminum:
Offers longer lifespan and better performance for vehicles, construction materials, and household appliances.
Custom metal wire alloys for 3D printing technologies could also be developed using this process.
Potential for New Alloys:
Solid phase alloying can be applied to any metal combination, enabling the creation of entirely new alloys previously unachievable.
Cindy Powell of the Pacific Northwest National Laboratory highlighted the revolutionary potential of this solid-state manufacturing process.
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