PNNL

Abstract

Transitioning vehicle manufacturing to predominantly recycled materials offers significant energy savings and reduces CO2 emissions. However, impurities, particularly in recycled light alloys like aluminum, pose limitations and hinder increased recycling in conventional manufacturing. Solid phase processing (SPP) presents a more efficient and environmentally friendly method for recycling secondary aluminum alloys. By breaking down impurities into smaller sizes and redistributing them uniformly, SPP prevents these impurities from initiating cracks under external loads, thereby enhancing the overall performance of recycled materials. Nevertheless, determining the threshold level of impurities—affected by variations in type, concentration, and size—can be time-consuming. This study aims to expedite this process by developing a rapid screening methodology. This approach will generate bulk-scale samples with gradient impurity concentrations, facilitating quicker assessments of optimal levels.