Aluminium recycling: A critical review of iron-bearing intermetallics in aluminium alloys
Hiren R. Kotadia, N. Bareker, M.H. Khan, Juan Ignacio Ahuir‐Torres, A. Das
Abstract
This review provides a comprehensive analysis of the current understanding of Fe-bearing intermetallic compounds (IMCs) in cast and wrought aluminium (Al) alloys, also covering their significance in recycling and sustainable materials development. It explores the various types of Fe-bearing IMCs, their nucleation and growth mechanisms under diverse processing conditions, with a particular focus on chemical, physical, and thermal modification strategies aimed at mitigating their detrimental effects. The review further examines the impact of these IMCs on defect formation, mechanical performance, and corrosion resistance. While Al recycling offers substantial energy savings (up to 95 %), the accumulation of impurities, notably Fe. This work provides practical insights to guide materials scientists and engineers in optimising processing conditions for Al alloys with elevated Fe content or those derived from recycled scrap. Understanding the behaviour and control of Fe-bearing IMCs is essential for improving alloy performance and advancing the sustainable production of Al.