On the Role of Processing Parameters in Producing Recycled Aluminum AA6061 Based Metal Matrix Composite (MMC-AlR) Prepared Using Hot Press Forging (HPF) Process

Abstract

Solid-state recycling, which involves the direct recycling of scrap metal into bulk material using severe plastic deformation, has emerged as a potential alternative to the conventional remelting and recycling techniques. Hot press forging has been identified as a sustainable direct recycling technique that has fewer steps and maintains excellent material performance. An experimental investigation was conducted to explore the hardness and density of a recycled aluminum-based metal matrix composite by varying operating temperature and holding time. A mixture of recycled aluminum, AA6061, and aluminum oxide were simultaneously heated to 430, 480, and 530 • C and forged for 60, 90, and 120 min. We found a positive increase in microhardness and density for all composites. The hardness increased approximately 33.85%, while density improved by about 15.25% whenever the temperature or the holding time were increased. Based on qualitative analysis, the composite endures substantial plastic deformation due to the presence of hardness properties due to the aluminum oxide embedded in the aluminum matrix. These increases were significantly affected by the operating temperature; the holding time also had a subordinate role in enhancing the metal matrix composite properties. Furthermore, in an effort to curb the shortage of primary resources, this study reviewed the promising performance of secondary resources produced by using recycled aluminum and aluminum oxide as the base matrix and reinforcement constituent, respectively. This study is an outline for machining practitioners and the manufacturing industry to help increase industry sustainability with the aim of preserving the Earth for our community in the future.

Effect of Holding Time on Density and Morphological Property of Aluminium Composite Using Recycled Materials by Stir Casting Method

“…Insufficient ht influences the density of the composites by way of creating a huge vacuum between the chips and the matrix as such lowering the density values. Increasing the ht enhances the bonding between the matrix and the reinforcements which would eventually lead to higher and improved density [9]. This could evidently be observed in Fig.…”

Statistical Optimization by the Response Surface Methodology of Direct Recycled Aluminum-Alumina Metal Matrix Composite (MMC-AlR) Employing the Metal Forming Process

“…%), and other elements (<0.01 wt. %) [23]. The composition of 99.9 % purity Al 2 O 3 (Sigma-Aldrich, Saint Louis, MO, USA) with a size of~1 µm mainly consisted of aluminum (Al) and oxide (O).…”

“…Processes 2020, 8, x FOR PEER REVIEW 3 of 19 the possibility of improving the anisotropic properties by solidifying the grid and adjusting the microstructural properties, for example the porosity [4,22,23].…”

“…Thus, it is beneficial to utilize the hot press forging process, to achieve a close net-shaped product, without causing such damage. Besides, such a plastic deformation approach offers the possibility of improving the anisotropic properties by solidifying the grid and adjusting the microstructural properties, for example the porosity [4,22,23].…”

Multiresponse Optimization and Environmental Analysis in Direct Recycling Hot Press Forging of Aluminum AA6061

“…Additional research in this particular study area is highly recommended for further environmental conservation [14,15]. Hot press forging (HPF), in any case, has shown itself to be a promising elective technique for reusing aluminum as the loss from the machining procedure shows magnificent potential as far as quality and pliancy [16,17,18,19,20,21].…”