Abstract: Recycling is a major consideration in continued aluminum use due to the enormous demand for high quality products. Some impurity elements gradually accumulate through the repetitive reuse of aluminum alloy scrap. Of them, the iron content should be suppressed under the allowed limit. In the present research, a novel separation method was introduced to remove primary iron-rich intermetallic compounds by centrifuga-tion during solidifi cation of Al-Si-Fe alloys. This method does not use the density difference between two phases as in other centrifugal methods, but uses the order of solidifi cation in Al-Si-Fe alloys, because iron promotes the formation of intermetallic compounds with other alloying elements as a primary phase. Two Al-Si-Fe alloys which have different iron contents were chosen as the starting materials. The iron-rich phase could be efficiently removed by centrifuging under a centrifugal force of 40 g. Coarse intermetallic compounds were found in the sample inside the crucible, while rather fi ne intermetallic compounds were found in the sample outside the crucible. Primary intermetallic compounds were linked to each other via aluminum-rich matrix, and formed like a network. The highest iron removal fraction is 67% and the lowest one is 7% for Al-12Si-1.7Fe alloy. And they are 82% and 18% for Al-12Si-3.4Fe alloy, respectively.
Most of the aluminum components for cars are made by high pressure die casting. High pressure die casting is an efficient and economical process which is appropriate for high speed production and high dimensional accuracy of the components.Practically all die cast aluminum alloys are pro-duced using recycled materials [1]. However the casting yield in high pressure die casting is rather low because the portion of biscuit, runner and over-flow compared to the casting itself is high due to its thin and complicated shape. Lots of scrap is generated, which is used for subsequent melting.
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