Alloy Design Pathway for High‐Value Utilization of Recycled Aluminum Cans

Against the backdrop of carbon neutrality targets and resource constraints, the upcycling of recycled aluminum plays a critical role in reducing lifecycle carbon emissions, mitigating dependence on primary aluminum, and expanding the applications of aluminum alloys. In this study, Al–Mg–Si–Cu alloys are fabricated from recycled aluminum beverage can stock, and the influence of Si content (expressed as the Mg/Si ratio) on mechanical properties and intergranular corrosion (IGC) resistance is systematically investigated. Key design guidelines are established. The consumption of Si by Mn, Cr, Fe, and other transition elements forming precipitates must be considered when determining the Mg/Si ratio. When Mg/Si ≤ 1.04, alloys exhibit a yield strength above 394 MPa, tensile strength above 425 MPa, and elongation of at least 8%. IGC susceptibility increases with decreasing Mg/Si. When the Mg/Si ratio is no less than 0.88, the alloy exhibits excellent IGC. The enhanced performance is primarily attributed to the formation of abundant submicron α‐Al(MnFeCr)Si dispersoids, which refine the grains, increase the fraction of low‐angle grain boundaries, and mitigate the detrimental effects of coarse Fe‐rich phases. These findings provide a feasible pathway and quantitative design basis for the high‐value utilization of recycled can‐based aluminum.