Upcycled High-Strength Aluminum Alloys from Scrap through Solid-Phase Alloying

Although recycling secondary aluminum can lead to energy consumption reduction compared to primary aluminum manufacturing, products produced by traditional melt-based recycling processes are inherently limited in terms of alloy composition and microstructure, and thus final properties. To overcome the constraints associated with melting, we have developed a novel solid-phase recycling and simultaneous alloying method. This innovative process enables the alloying of 6063 aluminum scrap with copper, zinc, and magnesium, to form a nanocluster-strengthened high-performance aluminum alloy with a composition and properties akin to 7075 aluminum alloy. The unique nanostructure with high density of Guinier-Preston zones and uniformly precipitated nanoscale η'/Mg(CuZn) 2 strengthening phases, enhances both yield and ultimate tensile strength by > 200%. By delivering high-performance products from scrap that are not just recycled but upcycled , this scalable manufacturing approach offers a new paradigm of metals reuse, with the option for on-demand upcycling of a variety of metallic materials from scrap sources.