High-throughput CALPHAD-guided design and experimental study on the development of a novel multicomponent as-cast Al-Si-Cu-Zn-Fe-Mn-Mg based alloy through the direct melting of post-consumer scrap

Abstract

In the present study, high-throughput CALPHAD calculations are performed to obtain the phase equilibria and solidification properties of an as-cast aluminum alloy containing Si, Cu, Fe, Zn, Mn and Mg. The appropriate alloy compositions were reversely designed to optimize the solidification interval, promote eutectic solidification of Si and Fe-rich phases, and avoid the formation of primary intermetallic compounds, and the overall reduction of other type of intermetallic compounds. The alloy was developed entirely from post-consumer scrap by two-step simple low-cost gravity casting technology that is easily scalable. To validate the CALPHAD-guided design, the microstructure and mechanical properties of the developed alloy were studied. The developed alloy successfully demonstrated the feasibility of creating alloys from post-consumer scrap that meet industry standards, using only adjusting elements, grain refiners and modifiers. Consequently, this study provides a viable approach to increase the scrap recycling rate and contributes to the industrialization of aluminum castings with a low carbon footprint. • The alloy was developed entirely from post-consumer scrap by two-step simple low-cost gravity casting technology that is easily scalable. • The employment of high-throughput Calphad calculations enabled the rapid identification of a promising alloy composition, which was then validated through experimental characterization. • The designed alloy shows a good combination of strength and ductility. The ductility is more than 50 % higher than that of related primary aluminum alloys for sand and permanent mold casting. • This work contributes to the development of sustainable materials and demonstrates the potential for post-consumer scrap to be transformed into high-performance alloys.

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