The Need
Secondary aluminum alloys are gaining attention for their low carbon footprint, using only ~5% of the energy required for primary alloys. However, high impurity levels, especially iron, cause brittleness. Current mitigation involves manganese additions. A new alloy that reduces iron’s effects, avoids copper additions, and minimizes magnesium removal needed during recycling to enhance strength and elongation, expanding secondary alloy applications.

The Technology
OSU researchers have developed a novel secondary aluminum alloy formulation that significantly enhances mechanical performance while maintaining compatibility with existing manufacturing processes. The alloy has been engineered to address key limitations of conventional secondary alloys, offering improved ductility and strength without relying on costly or hazardous processing steps. This advancement supports broader adoption of recycled aluminum in demanding applications, aligning with industry goals for sustainability and cost-efficiency.

Potential Commercial Applications
• Automotive components
• Consumer electronics casings
• Appliance parts
• Industrial machinery components
• Die-cast parts in general manufacturing

Benefits/Advantages
• Improved ductility: Elongation increased from 3.1% to 5.1%
• Cost reduction: Lower Cu content and reduced need for Mg chlorination during recycling
• Enhanced sustainability: Enables broader use of recycled aluminum
• Industrial scalability: Compatible with existing die-casting infrastructure
• Microstructural control: Refined intermetallic phases for better mechanical integrity