Direct hot rolling as a solid-state recycling process for green sheets production

Research output: Contributions to collected editions/worksArticle in conference proceedingsResearchpeer-review

Authors

  • Mohamad El Mehtedi
  • Noomane Ben Khalifa
  • Pasquale Buonadonna
  • Rayane El Mohtadi
  • Gianluca Marongiu
  • Francesco Aymerich
  • Mauro Carta

With the increasing demand for sustainable solutions in the recycling of aluminum alloys, solid-state recycling (SSR) offers an energy-efficient alternative by avoiding the melting phase, which typically leads to high energy consumption and material loss. This study presents a novel SSR process utilizing direct hot rolling to recycle aluminum alloy chips (EN AW-5754). The main objective is to evaluate this process's feasibility and assess the recycled sheets' mechanical and microstructural properties. Aluminum alloy chips were produced from the turning process of EN AW-AA5754 bars. The chips were compacted and subsequently heat-treated at 400°C for 2 hours. The compacted samples were then hot rolled in multiple passes, with a final cold rolling step to achieve a final thickness of 0,8 mm. Mechanical properties and microstructure were analyzed using tensile testing machine and SEM-EBSD technique. The recycled samples demonstrated mechanical properties comparable to those of reference material. SEM/EBSD analysis revealed broken oxides and a layered grain structure due to the prior chips’ boundaries. Overall, the results confirm that direct hot rolling can be a viable recycling method for aluminum alloys, offering significant energy and material savings compared to conventional processes.

Original languageEnglish
Title of host publication28th International ESAFORM Conference on Material Forming, ESAFORM 2025
EditorsPierpaolo Carlone, Luigino Filice, Domenico Umbrello
Number of pages11
PublisherAssociation of American Publishers
Publication date2025
Pages1449-1459
ISBN (print)9781644903599
DOIs
Publication statusPublished - 2025
Event28th International ESAFORM Conference on Material Forming, ESAFORM 2025 - Paestum, Italy
Duration: 07.05.202509.05.2025

Bibliographical note

Publisher Copyright:
© 2025, Association of American Publishers. All rights reserved.

    Research areas

  • Chips, Direct Hot Rolling, EBSD, EN AW-5754, Solid-State Recycling, Tensile Tests
  • Engineering