Wrought aluminum alloys (WAAWrought Aluminum Alloys (WAA)) produced from post-consumer scrapScrap (PCSPost-Consumer Scrap (PCS)) can meet standard chemical compositionChemical composition requirements, yet their mechanical propertiesMechanical properties—particularly fatigue resistance—remain below those of alloys made from primary aluminumAluminum (PA). This study examines the causes of this gap, with emphasis on residual tramp and trace elements inherent to PCSPost-Consumer Scrap (PCS), even when sourced from closed-loop, single-alloy streams. Industrial-scale alloys 2024, 6061, and 7075 were produced from both high-grade PCSPost-Consumer Scrap (PCS) and low-carbonCarbon primary aluminumAluminum. While target compositions were achieved in both cases, PCSPost-Consumer Scrap (PCS)-derived alloys consistently showed inferior dynamic propertiesProperties. The results confirm that compositional compliance alone does not guarantee performance equivalence when elements such as Fe, Si, Na, Pb, and Bi are present, even at ppm levels. These findings highlight the need to redefine PCSPost-Consumer Scrap (PCS) qualityQuality metrics for high-end applications, shifting from composition-based specifications toward performance-oriented standards that explicitly address tramp and trace elements.

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Upcycling of Post-Consumer Scrap into Wrought Aluminum Alloys: Technological Challenges and Economic Viability

  • Varužan M. Kevorkijan

摘要

Wrought aluminum alloys (WAAWrought Aluminum Alloys (WAA)) produced from post-consumer scrapScrap (PCSPost-Consumer Scrap (PCS)) can meet standard chemical compositionChemical composition requirements, yet their mechanical propertiesMechanical properties—particularly fatigue resistance—remain below those of alloys made from primary aluminumAluminum (PA). This study examines the causes of this gap, with emphasis on residual tramp and trace elements inherent to PCSPost-Consumer Scrap (PCS), even when sourced from closed-loop, single-alloy streams. Industrial-scale alloys 2024, 6061, and 7075 were produced from both high-grade PCSPost-Consumer Scrap (PCS) and low-carbonCarbon primary aluminumAluminum. While target compositions were achieved in both cases, PCSPost-Consumer Scrap (PCS)-derived alloys consistently showed inferior dynamic propertiesProperties. The results confirm that compositional compliance alone does not guarantee performance equivalence when elements such as Fe, Si, Na, Pb, and Bi are present, even at ppm levels. These findings highlight the need to redefine PCSPost-Consumer Scrap (PCS) qualityQuality metrics for high-end applications, shifting from composition-based specifications toward performance-oriented standards that explicitly address tramp and trace elements.