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<p>This study presents a novel method for recycling aluminum chips through direct hot rolling, eliminating the need for conventional melting processes. The solid-state recycling (SSR) approach reduces energy consumption, minimizes material loss, and mitigates environmental impact. Chips of pure aluminum (99.9wt.%) produced by turning were compacted, heat treated and subjected to hot rolling. Both compacted chips and parent-bulk material underwent the same rolling schedule achieving the final thickness of 0.8&#xa0;mm. The produced sheets were subjected to microhardness, tensile tests, microstructure analysis (optical and SEM-EBSD techniques), density measurements, and corrosion tests. The recycled sheets exhibited average mechanical properties close to those of the parent-bulk material, albeit with higher data dispersion, with an Ultimate Tensile Strength (UTS) of 94.6 vs. 94.4&#xa0;MPa, elongation at fracture (A%) of 7.0 compared to 7.1%, microhardness of 26.2 vs. 28.4 HV respectively, and lower corrosion rate for recycled chips. Overall, the results demonstrate the fundamental feasibility of direct hot rolling as a solid-state recycling route for pure aluminum chips under controlled conditions.</p>

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Solid-state recycling of pure aluminum chips via direct hot rolling: mechanical, microstructural, and corrosion insights

  • 期刊论文

  • 出版模式：

    开放获取

  • 发表日期：

    2026年5月27日

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  • Mauro Carta,
  • Pasquale Buonadonna,
  • Mohamad El Mehtedi

摘要

This study presents a novel method for recycling aluminum chips through direct hot rolling, eliminating the need for conventional melting processes. The solid-state recycling (SSR) approach reduces energy consumption, minimizes material loss, and mitigates environmental impact. Chips of pure aluminum (99.9wt.%) produced by turning were compacted, heat treated and subjected to hot rolling. Both compacted chips and parent-bulk material underwent the same rolling schedule achieving the final thickness of 0.8 mm. The produced sheets were subjected to microhardness, tensile tests, microstructure analysis (optical and SEM-EBSD techniques), density measurements, and corrosion tests. The recycled sheets exhibited average mechanical properties close to those of the parent-bulk material, albeit with higher data dispersion, with an Ultimate Tensile Strength (UTS) of 94.6 vs. 94.4 MPa, elongation at fracture (A%) of 7.0 compared to 7.1%, microhardness of 26.2 vs. 28.4 HV respectively, and lower corrosion rate for recycled chips. Overall, the results demonstrate the fundamental feasibility of direct hot rolling as a solid-state recycling route for pure aluminum chips under controlled conditions.