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<p>The conventional production of hypereutectic aluminum-silicon alloys (silumins) is economically and environmentally costly due to its reliance on primary silicon. This study presents a sustainable and efficient method for producing these alloys by recycling amorphous microsilica, a waste by-product from silicon production. The optimal process involved reduction roasting of a compacted mixture of microsilica, aluminum powder, and cryolite at 800&#xa0;°C, followed by induction melting of the product with aluminum. This approach achieved near-complete reduction of SiO₂ to silicon and its subsequent assimilation into the melt, yielding hypereutectic silumins with a silicon content exceeding 16 wt%. The technology offers a significant cost advantage by substituting expensive crystalline silicon with low-cost industrial waste, simultaneously addressing waste valorization and reducing the environmental footprint of alloy production.</p>

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Recycling silicon waste into hypereutectic aluminum-silicon alloys

  • 期刊论文

  • 发表日期：

    2026年3月3日

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  • Mikhail P. Kuz’min,
  • Alina S. Kuz’mina,
  • Marina Yu. Kuz’mina

摘要

The conventional production of hypereutectic aluminum-silicon alloys (silumins) is economically and environmentally costly due to its reliance on primary silicon. This study presents a sustainable and efficient method for producing these alloys by recycling amorphous microsilica, a waste by-product from silicon production. The optimal process involved reduction roasting of a compacted mixture of microsilica, aluminum powder, and cryolite at 800 °C, followed by induction melting of the product with aluminum. This approach achieved near-complete reduction of SiO₂ to silicon and its subsequent assimilation into the melt, yielding hypereutectic silumins with a silicon content exceeding 16 wt%. The technology offers a significant cost advantage by substituting expensive crystalline silicon with low-cost industrial waste, simultaneously addressing waste valorization and reducing the environmental footprint of alloy production.