Compaction of aluminium foil and its effect on oxidation and recycling yield

This is a post-peer-review, pre-copyedit version of an article published in Light Metals 2021, Part of the The Minerals, Metals & Materials Series book series (MMMS). The final authenticated version is available online at: https://doi.org/10.1007/978-3-030-65396-5_96One of the problems when recycling aluminium is its oxidation and consequent metal loss. This is especially critical for the thin sheet/foil materials used for food packaging applications. Compacting the scrap into briquettes may partly reduce such losses in addition to facilitate transport and storage. Shredded aluminium materials of different thicknesses (15-300 microns) were compacted into cylindrical briquettes of 4 cm diameter, each weighting 20 g by uniaxial pressure or moderate-pressuretorsion. A sub-set of briquettes and chips was subsequently oxidized at 650 C, while a sub-set was left untreated. Finally, all samples were re-melted under molten protective salt-flux. Compacting reduced the specific oxidation during the heat-treatment and promoted the coalescence and yield for the heat-treated materials. Both effects were most significant for the thinnest foil in the study (15 microns). The material thickness influenced the porosity and surface roughness of the resultant briquette, as well as the pressure required to reach a given bulk density.acceptedVersio

In Situ Measurements of the Chemical Stability of a Cast Aluminum Alloy Embedded in a Cement Paste with a High Amount of Supplementary Cementitious Material

In traditional reinforced concrete, the alkaline pore solution which passivates the steel rebars will get neutralized with time in an exposed environment. Therefore, to prevent corrosion initiation, the permeability of the concrete is reduced and extra-thick concrete covers the steel rebars. Aluminum is passive in the neutralized environment, but the calcium hydroxide formed during the cement hydration will dissolve the aluminum. By substituting 55% of the cement in traditional cement paste with fast reactive supplementary cementitious material (SCM), aluminum will be compatible over time. In the initial state however, before the SCM consumes the hydroxide formed during the rapid cement hydration by the pozzolanic reaction, aluminum may corrode. Hydrogen gas then develops, resulting in a porous cement region enclosing the rebars with potentially reduced bond strength. In the present work, the chemical stability of a sand-cast aluminum lattice embedded in a paste where cement is replaced by 55% calcined kaolinitic clay is investigated by gas chromatography and open-circuit potential during the cement hydration. The hydrogen gas development stagnated for all measurements, indicating that aluminum is compatible with the novel cement paste. Two stable potentials were observed for the non-heat-treated samples, indicating the formation of a metastable complex. Being able to use aluminum-reinforced concrete constructions would result in an extraordinary long service life with low cement consumption, which will potentially result in a substantial reduction in the third-largest CO2 emitting industry.publishedVersio

Comparing intergranular corrosion in Al‐Mg‐Si‐Cu alloys with and without α‐Al(Fe,Mn,Cu)Si particles

In this study, a model alloy without Fe and Mn additions, is compared with a commercial AA6005 alloy to further understand how the α‐Al(Fe,Mn,Cu)Si particles affect intergranular corrosion (IGC) behaviour. Both alloys were subjected to an accelerated IGC test for durations ranging from 1 to 120 h. Microstructures were studied using scanning and transmission electron microscopy, and electron backscatter diffraction. The presence of α‐Al(Fe,Mn,Cu)Si particles yields significantly more uniform IGC attacks and higher corrosion rates. However, the maximum depth of IGC attacks reaches similar values after ~24 h of exposure. This is attributed to the formation of Cu‐rich particles along the grain boundaries during the corrosion process, which further catalyses the cathodic reactions.publishedVersio

Comparative study of eutectic Al-Si alloys manufactured by WAAM and casting

Wire and arc additive manufacturing (WAAM) of metallic materials is expected to become part of the new industrial revolution. The possibilities for complex designs and superior mechanical properties can in many cases replace traditional manufacturing processes such as casting. In order to benchmark the properties of aluminium WAAM components, a comparative study was performed with two different casting techniques: permanent casting with steel mould and sand mould casting. Aluminium-silicon alloys with near eutectic composition were used for the comparison. Porosity levels, secondary dendrite arm spacing, grain size distribution, tensile strength and microhardness were considered for the comparison. The WAAM material exhibited superior mechanical properties originating from a finer dendritic and eutectic microstructure compared with the castings. A slight anisotropy in tensile ductility was observed in the WAAM material, probably due to a coarse microstructural zone between individual beads. All investigated materials had low levels of porosity, < 1% by area fraction. The comparative study has shown that WAAM of aluminium-silicon alloys is well suited for high-integrity applications.publishedVersio

In Situ Measurements of the Chemical Stability of a Cast Aluminum Alloy Embedded in a Cement Paste with a High Amount of Supplementary Cementitious Material

In traditional reinforced concrete, the alkaline pore solution which passivates the steel rebars will get neutralized with time in an exposed environment. Therefore, to prevent corrosion initiation, the permeability of the concrete is reduced and extra-thick concrete covers the steel rebars. Aluminum is passive in the neutralized environment, but the calcium hydroxide formed during the cement hydration will dissolve the aluminum. By substituting 55% of the cement in traditional cement paste with fast reactive supplementary cementitious material (SCM), aluminum will be compatible over time. In the initial state however, before the SCM consumes the hydroxide formed during the rapid cement hydration by the pozzolanic reaction, aluminum may corrode. Hydrogen gas then develops, resulting in a porous cement region enclosing the rebars with potentially reduced bond strength. In the present work, the chemical stability of a sand-cast aluminum lattice embedded in a paste where cement is replaced by 55% calcined kaolinitic clay is investigated by gas chromatography and open-circuit potential during the cement hydration. The hydrogen gas development stagnated for all measurements, indicating that aluminum is compatible with the novel cement paste. Two stable potentials were observed for the non-heat-treated samples, indicating the formation of a metastable complex. Being able to use aluminum-reinforced concrete constructions would result in an extraordinary long service life with low cement consumption, which will potentially result in a substantial reduction in the third-largest CO2 emitting industry

Precipitation, strength and work hardening of age hardened aluminium alloys

The strength and work hardening of age hardened AA6063 and AA6082 alloys have been investigated in terms of a detailed characterization of precipitate and dislocation structures obtained by TEM and SEM. Tensile and compression tests were performed at as quenched, peak aged and severely aged conditions. A strong work hardening in the as quenched condition was found, similar to AlMg alloys with twice as much alloying elements in solid solution. It was found that the initial work hardening rate and the critical failure strain are both smallest at the peak aged condition. During large deformations the needle-shaped precipitates are sheared uniformly by dislocations altering their orientations, which indicates extensive cross slip. In the overaged condition the early initial work hardening is larger than at the peak aged condition, but followed by a weak linear work hardening, apparently directly entering stage IV at a low strain. Cracked, needle-shaped precipitates were seen at larger strains

In Situ Measurements of the Chemical Stability of a Cast Aluminum Alloy Embedded in a Cement Paste with a High Amount of Supplementary Cementitious Material

In traditional reinforced concrete, the alkaline pore solution which passivates the steel rebars will get neutralized with time in an exposed environment. Therefore, to prevent corrosion initiation, the permeability of the concrete is reduced and extra-thick concrete covers the steel rebars. Aluminum is passive in the neutralized environment, but the calcium hydroxide formed during the cement hydration will dissolve the aluminum. By substituting 55% of the cement in traditional cement paste with fast reactive supplementary cementitious material (SCM), aluminum will be compatible over time. In the initial state however, before the SCM consumes the hydroxide formed during the rapid cement hydration by the pozzolanic reaction, aluminum may corrode. Hydrogen gas then develops, resulting in a porous cement region enclosing the rebars with potentially reduced bond strength. In the present work, the chemical stability of a sand-cast aluminum lattice embedded in a paste where cement is replaced by 55% calcined kaolinitic clay is investigated by gas chromatography and open-circuit potential during the cement hydration. The hydrogen gas development stagnated for all measurements, indicating that aluminum is compatible with the novel cement paste. Two stable potentials were observed for the non-heat treated samples, indicating the formation of a metastable complex. Being able to use aluminum-reinforced concrete constructions would result in an extraordinary long service life with low cement consumption, which will potentially result in a substantial reduction in the third-largest CO2 emitting industry

Effects of iron precipitation and novel metal screw extrusion on electrical conductivity and properties of AA1370 aluminium

In order to develop well-performing aluminium electrical conductors, the role of iron and processing method on electrical and mechanical properties was studied for an AA1370 alloy. Firstly, Ø3 mm cold drawn wires were subjected to a solid solution heat treatment (640 °C/1 h) followed by artificial aging at various temperatures in order to reveal the representative time-temperature-transformation (TTT)-diagram for Fe-rich precipitates. The highest precipitation rate occurred at 450 °C. Secondly, an identical AA1370 alloy was produced by the novel metal continuous screw extruder (MCSE) process into a new Ø3 mm wire. The as produced wire had a recrystallised outer layer and an elongated fibrous structure having a typical 〈0 0 1〉 texture in the center region. TEM investigations revealed Fe-rich precipitates at grain boundaries thus impeding grain growth to some extent. The screw extruded wire processed at 450 °C had a high conductivity (64.2%IACS) while being softer (UTS 65 MPa) than the cold drawn wire (UTS 164 MPa, 61.9%IACS). The correspondence between strength and electrical conductivity for cold drawn and screw extruded wires was compared to literature data for pure and dilute alloys. The screw extruded wire outperformed other alloys as to electrical conductivity, while being among the materials having lowest strength

The correlation between intergranular corrosion resistance and copper content in the precipitate microstructure in an AA6005A alloy

A positive correlation is observed between the amount of Cu incorporated in hardening precipitates and intergranular corrosion resistance in an artificially aged Cu-containing 6005A alloy. Three mechanisms have been identified to increase Cu absorption in hardening precipitates: by increasing aging temperature, by pre-deformation, and by slow cooling from solution heat treatment. These findings demonstrate the possibility for development of new processing routes to produce Cu-containing Al-Mg-Si alloys with improved corrosion resistance.acceptedVersio

Comparing intergranular corrosion in Al‐Mg‐Si‐Cu alloys with and without α‐Al(Fe,Mn,Cu)Si particles

In this study, a model alloy without Fe and Mn additions, is compared with a commercial AA6005 alloy to further understand how the α‐Al(Fe,Mn,Cu)Si particles affect intergranular corrosion (IGC) behaviour. Both alloys were subjected to an accelerated IGC test for durations ranging from 1 to 120 h. Microstructures were studied using scanning and transmission electron microscopy, and electron backscatter diffraction. The presence of α‐Al(Fe,Mn,Cu)Si particles yields significantly more uniform IGC attacks and higher corrosion rates. However, the maximum depth of IGC attacks reaches similar values after ~24 h of exposure. This is attributed to the formation of Cu‐rich particles along the grain boundaries during the corrosion process, which further catalyses the cathodic reactions