Methods of recycling aluminum alloys and purification thereof

Abstract

To provide methods of producing aluminum alloys purified from aluminum alloy scrap.SOLUTION: A method includes producing a melt of aluminum alloy scrap, adding one or more intermetallic former materials, producing iron-bearing intermetallic particles, removing the iron-bearing intermetallic particles, and solidifying the low-iron melt.SELECTED DRAWING: Figure 1b

Description

[Background technology]

[0001] Aluminum alloys are useful in a variety of applications. Some aluminum alloys are recyclable, and recycling such aluminum alloys conserves energy resources. In the United States and Canada, more than 5 million tons of aluminum are recycled each year. Summary of the Invention

[0002] Generally, the present disclosure relates to a method for producing a purified aluminum alloy from aluminum alloy scrap. In one embodiment, the aluminum alloy produced is a 3xx aluminum cast alloy. In another embodiment, the aluminum alloy produced is one of a 3xxx or 4xxx wrought aluminum alloy. Generally, the method described herein for producing a purified aluminum alloy includes melting aluminum alloy scrap, adding one or more intermetallic former materials to the melt, and reacting the intermetallic former materials, such as Si and / or Mn, with elemental iron of the aluminum alloy scrap, thereby producing iron-bearing intermetallic particles. The produced iron-bearing intermetallic particles may then be removed (e.g., by filtration). The addition of the intermetallic former materials, Si and / or Mn, produces an alloy with increased amounts of Si and / or Mn, producing a 3xx aluminum cast alloy, or one of a 3xxx or 4xxx wrought aluminum alloy. The addition of intermetallic compound-forming materials to the melt increases the temperature window over which the intermetallic particles can be removed, and therefore increases the volume fraction of iron-containing intermetallic particles available for removal. Thus, the addition of intermetallic compound-forming materials to the melt can facilitate the production of suitable end-use alloys, facilitate the removal of iron from aluminum scrap at industrially applicable temperature ranges, and facilitate the reduction of iron content in aluminum alloys.

[0003] In one embodiment, and referring to FIG. 1a, aluminum scrap is melted by conventional methods (120) and an intermetallic compound-forming material is added to the melt (130). The addition of the intermetallic compound-forming material produces iron-containing intermetallic particles (140), for example, by reaction of the intermetallic compound-forming material with iron in the melt (141). After or during their formation, the iron-containing intermetallic particles can be removed (150) by any suitable method, such as, but not limited to, filtration or sedimentation. Finally, the melt solidifies (160) to produce a refined aluminum alloy (161).

[0004] More specifically, referring to FIG. 1b, aluminum alloy scrap containing iron (Fe) (111) is obtained for recycling (110). For example, the initial iron (Fe) content may be 0.2 wt.% or more (112). In one embodiment, the initial iron (Fe) content may be 0.3 wt.% or more. In another embodiment, the initial iron (Fe) content may be 0.4 wt.% or more. In yet another embodiment, the initial iron (Fe) content may be 0.5 wt.% or more. In another embodiment, the initial iron (Fe) content may be 0.6 wt.% or more. In yet another embodiment, the initial iron (Fe) content may be 0.7 wt.% or more. In another embodiment, the initial iron (Fe) content may be 0.8 wt.% or more. In yet another embodiment, the initial iron (Fe) content may be 0.9 wt.% or more. In another embodiment, the initial iron (Fe) content may be 1.0 wt.% or more. In yet another embodiment, the initial iron (Fe) content may be 1.5 wt.% or more. In other embodiments, the initial iron (Fe) content may be greater than or equal to 2.0 wt.%. In yet other embodiments, the initial iron (Fe) content may be greater than or equal to 3.0 wt.%.

[0005] Aluminum alloy scrap is melted (120) by conventional methods and an intermetallic compound-forming material, such as silicon (Si) and / or manganese (Mn), is added (131) to the melt. The intermetallic compound-forming material is added in an amount sufficient to generate (140) iron-containing intermetallic particles in the melt, such as by reaction (141) of the Si and / or Mn with iron in the melt. The generation occurs as a result of cooling the melt from a first temperature to a second temperature. In some embodiments, the first temperature is the liquidus temperature of the melt. In other embodiments, the first temperature is greater than the liquidus temperature of the melt. In some embodiments, the second temperature is greater than the solidification temperature of fcc aluminum. In some embodiments, the second temperature is less than the solidification temperature of aluminum and greater than the solidus temperature of the melt. The addition of intermetallic compound-forming material (130) is in an amount sufficient to provide an increase (132) in the temperature difference between the liquidus temperature of the melt and the solidification temperature of fcc aluminum (e.g., a purification temperature window, ΔT) in which the iron-containing intermetallic particles may be formed. Typically, the addition of intermetallic compound-forming material (130) provides a temperature window between a first temperature and a second temperature of at least 10° C. (133). Within the temperature range (possibly at or below the second temperature), the intermetallic particles may be removed (150) by methods such as, but not limited to, filtering or settling the melt. The melt, now iron-lean from the removal (150), is then solidified (160) (e.g., cooled to a temperature below the solidus temperature of the iron-lean melt). The iron-lean melt is solidified (160) by adding an intermetallic compound-forming material (130), producing iron-containing intermetallic particles (140), and removing at least a portion of the iron-containing intermetallic particles (150) to produce a refined aluminum alloy (161). In one embodiment, one of a 3xxx or 4xxx wrought aluminum alloys can be produced (162). In another embodiment, a 3xx cast aluminum alloy can be produced (163). The refined aluminum alloy has an iron content that is less than the initial iron content (164) due to the removal of the iron-containing particles (150).For example, the iron (Fe) content of refined aluminum alloys is less than 0.5 wt% (165).

[0006] As described above, an intermetallic compound forming material is added to the melt (131) to generate iron-containing intermetallic particles in the melt (140). 15 (Fe:Mn) 3 S 2 Intermetallic particles with a composition of Al are produced in the temperature range between the liquidus of the melt and the solidification temperature of fcc aluminum. 15 (Fe:Mn) 3 S 2 The particles solidify below the liquidus (i.e., Al 15 (Fe:Mn) 3 S 2 is the first solid and forms below the liquidus. In one embodiment, the addition of the intermetallic compound forming materials Si and / or Mn results in the formation of iron-containing intermetallic particles Al 15 (Fe:Mn) 3 S 2 is removed (150), and the temperature range between the liquidus of the melt and the freezing temperature of the fcc aluminum alloy is more than 10°C (133).

[0007] The aluminum alloy scrap is obtained in various forms (110). For example, the aluminum alloy scrap is obtained as automobile scrap, aircraft scrap, beverage can scrap, electronics scrap, municipal waste scrap, etc., where industrial applications of the aluminum alloy are found. Thus, the aluminum alloy scrap is a collection of any type of scrap (e.g., mixed-stream scrap). In one embodiment, the aluminum alloy scrap is mixed-stream aluminum alloy scrap. Similarly, the scrap aluminum alloy can be produced as part of the normal production of ingots, billets, or shape casting of parts. In this regard, the aluminum alloy scrap can be composed of at least a first scrap and a second scrap that are heterogeneous (e.g., have relatively different compositions). In some embodiments, the aluminum alloy scrap includes at least a first scrap and a second scrap that have relatively different compositions.

[0008] Melting (120) can be performed by any suitable method, such as methods known in the art. After melting (120), the addition of the intermetallic compound-forming material can be performed at any suitable time. For example, it can be added (a) before melting, (b) during melting of the scrap, or (c) after the scrap exceeds the liquidus temperature (e.g., after melting). Furthermore, the intermetallic compound-forming material can be added in any suitable form. For example, the intermetallic compound-forming material can be added in a relatively pure form. For example, silicon can be added as relatively pure silicon and manganese can be added as relatively pure manganese. Furthermore, an alloy including an intermetallic compound-forming material can be used as a source of the intermetallic compound-forming material. For example, a silicon-containing aluminum alloy or a manganese-containing aluminum alloy can be added to increase the silicon and / or manganese content of the melt. In one embodiment, the intermetallic compound-forming material manganese can be added as a manganese master alloy (e.g., Mn>10 wt. %, balance essentially aluminum).

[0009] The intermetallic compound-forming material can be added as scrap itself, in addition to a relatively pure form. For example, the aluminum alloy scrap can include at least a first scrap and a second scrap. In this regard, the first scrap can be an aluminum alloy having insufficient intermetallic compound-forming material to achieve removal of iron-containing intermetallic compound particles. The second scrap can be an aluminum alloy scrap having sufficient intermetallic compound-forming material to achieve removal of iron-containing intermetallic compound particles in combination with the at least first scrap. Furthermore, the process described herein is not limited to the addition of at least a first and a second scrap. For example, the first and second scraps include aluminum alloy scrap, and the additional intermetallic compound-forming material can be added in other forms that can achieve removal and / or increased removal of iron-containing intermetallic compound particles for the at least a first and a second scrap.

[0010] As discussed above, the addition of sufficient amounts of intermetallic compound formers (e.g., silicon (Si) and / or manganese (Mn)) (131) can provide an increase in the temperature difference between the liquidus temperature of the melt and the freezing temperature of the fcc aluminum (sometimes referred to herein as the "refining temperature range") (132). The iron-containing intermetallic particles can be removed at a refining temperature range (133) of at least 10°C. In one embodiment, the refining temperature range is at least 15°C. In another embodiment, the refining temperature range is at least 20°C. In yet another embodiment, the refining temperature range is at least 30°C. In another embodiment, the refining temperature range is at least 40°C. In yet another embodiment, the refining temperature range is at least 50°C. In another embodiment, the refining temperature range is at least 60°C. In yet another embodiment, the refining temperature range is at least 70°C. In another embodiment, the refining temperature range is at least 80°C. In yet another embodiment, the refining temperature range is at least 100°C.

[0011] After or during their formation, the iron-containing intermetallic particles can be removed by a suitable method, such as, but not limited to, filtration or settling, and combinations thereof (150). For example, filtration of the iron-containing intermetallic particles can be performed using various filters, such as filters made from refractory filter materials. Suitable refractory filter materials can include, but are not limited to, alumina, silica, silicon carbide, silicon nitride, calcium oxide, graphite, carbon, and the like. In some embodiments, the iron-containing intermetallic particles are removed by a filter medium that includes at least one refractory filter material. In this regard, multiple refractory filter materials can be used in one filter to facilitate the removal of the iron-containing intermetallic particles from the melt. Some suitable refractory filters are described in U.S. Pat. No. 5,126,047.

[0012] The process described herein results in a solidified aluminum alloy (160) that is a refined aluminum alloy (161) having an iron content that is less than the initial iron content of the aluminum alloy scrap (164). In one embodiment, the refined aluminum alloy obtained by the process has an iron content that is at least 10% less than the aluminum alloy scrap. As a non-limiting example, aluminum alloy scrap having an initial iron content of 0.8% by weight can be refined to have an iron content that is 10% less. In this example, the aluminum alloy scrap having an initial iron content of 0.8% by weight will have an iron content of 0.72% by weight (0.8% by weight x (100% - 10%)) after refinement. In one embodiment, the iron content after refinement is 15% less than the initial iron content. In another embodiment, the iron content after refinement is 20% less than the initial iron content. In yet another embodiment, the iron content after refinement is 25% less than the initial iron content. In another embodiment, the iron content after refinement is 35% less than the initial iron content. In yet another embodiment, the iron content after purification is 45% less than the initial iron content. In another embodiment, the iron content after purification is 60% less than the initial iron content. In yet another embodiment, the iron content after purification is 75% less than the initial iron content. In another embodiment, the iron content after purification is 85% less than the initial iron content.

[0013] In another aspect, the refined aluminum alloy has an iron (Fe) content of 1.80 wt.% or less (165). In one embodiment, the refined aluminum alloy has an iron (Fe) content of 1.5 wt.% or less. In another embodiment, the refined aluminum alloy has an iron (Fe) content of 1.2 wt.% or less. In yet another embodiment, the refined aluminum alloy has an iron (Fe) content of 1.0 wt.% or less. In another embodiment, the refined aluminum alloy has an iron (Fe) content of 0.8 wt.% or less. In yet another embodiment, the refined aluminum alloy has an iron (Fe) content of 0.5 wt.% or less. In another embodiment, the refined aluminum alloy has an iron (Fe) content of 0.40 wt.% or less. In yet another embodiment, the refined aluminum alloy has an iron (Fe) content of 0.35 wt.% or less. In another embodiment, the refined aluminum alloy has an iron (Fe) content of 0.30 wt.% or less. In yet another embodiment, the refined aluminum alloy has an iron (Fe) content of 0.25 wt.% or less. In another embodiment, the refined aluminum alloy has an iron (Fe) content of 0.20% by weight or less. In yet another embodiment, the refined aluminum alloy has an iron (Fe) content of 0.15% by weight or less. In another embodiment, the refined aluminum alloy has an iron (Fe) content of 0.12% by weight or less. In yet another embodiment, the refined aluminum alloy has an iron (Fe) content of 0.10% by weight or less.

[0014] Upon solidification (160), the refined aluminum alloy (161) can be cast from the low iron content melt as a shape cast part, or cast as an ingot / billet. The cast ingot or billet can also be remelted later for use in shape casting. Additionally, the cast ingot or billet can be remelted and combined with other materials to produce a desired aluminum alloy composition. For example, relatively pure aluminum can be added and / or other alloying additions can be added to produce a desired aluminum alloy. The cast ingot or billet can be processed by hot and / or cold working. These processes can include, for example, rolling, forging, extrusion, and / or stress relief by compression and / or stretching. Shape casting of the refined aluminum alloy can include any suitable shape casting method, including, for example, permanent mold casting, high pressure die casting, sand casting, investment casting, squeeze casting, and semi-solid casting.

[0015] The refined aluminum alloy may be a Si-based aluminum alloy. For example, the Si-based aluminum alloy may include a 3xx cast aluminum alloy or a 4xxx wrought aluminum alloy. As part of the refining process described herein, silicon (Si) is added to the melt, so that at least a portion of the silicon (Si) may remain in the refined aluminum alloy. The refined aluminum alloy may generally include at least 3.0% silicon (Si) by weight. In one embodiment, the refined aluminum alloy includes at least 4.0% silicon (Si). In another embodiment, the refined aluminum alloy includes at least 5.0% silicon (Si) by weight. In yet another embodiment, the refined aluminum alloy includes at least 6.0% silicon (Si) by weight. In another embodiment, the refined aluminum alloy includes at least 6.5% silicon (Si) by weight. In yet another embodiment, the refined aluminum alloy includes at least 7.0% silicon (Si) by weight. In another embodiment, the refined aluminum alloy includes at least 7.5% silicon (Si) by weight. In yet another embodiment, the refined aluminum alloy comprises at least 8.5 wt.% silicon (Si). In another embodiment, the refined aluminum alloy comprises at least 9.0 wt.% silicon (Si). In one embodiment, the refined aluminum alloy comprises no more than 23.0 wt.% silicon (Si). In another embodiment, the refined aluminum alloy comprises no more than 20.0 wt.% silicon (Si). In yet another embodiment, the refined aluminum alloy comprises no more than 15.0 wt.% silicon (Si).

[0016] As used herein, "3xx aluminum alloys" refers to aluminum casting alloys containing silicon (Si) as the major alloying element, which are described in the Aluminum Association's "Designations and Chemical Composition Limits for Aluminum Alloys in the Form of Castings and Ingot (2009)", also known as the Pink Sheets.

[0017] As used herein, "4xxx aluminum alloys" refers to wrought aluminum alloys containing silicon (Si) as the major alloying element, as described in the Aluminum Association's "International Alloy Designations and Chemical Composition Limits for Wrought Aluminum and Wrought Aluminum Alloys (2015)", also known as Teal Sheets.

[0018] In one embodiment, the method for producing a refined aluminum alloy described herein is used to produce the same aluminum alloy as disclosed in commonly owned U.S. Patent Publication No. 2013 / 0105045. In another embodiment, the method for producing a refined aluminum alloy described herein is used to produce the same aluminum alloy as disclosed in commonly owned U.S. Patent Publication No. 2017 / 0016092. In yet another embodiment, the method for producing a refined aluminum alloy described herein is used to produce the same aluminum alloy as disclosed in commonly owned WO 2017 / 027734.

[0019] The refined aluminum alloy may be a Mn-based aluminum alloy. For example, the Mn-based aluminum alloy may include a 4xxx wrought aluminum alloy. As part of the refining process described herein, manganese (Mn) is added to the melt, so that at least a portion of the manganese (Mn) may remain in the refined aluminum alloy. The refined aluminum alloy may generally include at least 0.05% manganese (Mn) by weight. In one embodiment, the refined aluminum alloy includes at least 0.10% manganese (Mn) by weight. In another embodiment, the refined aluminum alloy includes at least 0.20% manganese (Mn) by weight. In yet another embodiment, the refined aluminum alloy includes at least 0.30% manganese (Mn) by weight. In another embodiment, the refined aluminum alloy includes at least 0.40% manganese (Mn) by weight. In yet another embodiment, the refined aluminum alloy includes at least 7.0% manganese (Mn) by weight. In one embodiment, the refined aluminum alloy comprises 1.8 wt.% manganese (Mn) or less. In another embodiment, the refined aluminum alloy comprises 1.5 wt.% manganese (Mn) or less. In yet another embodiment, the refined aluminum alloy comprises 1.2 wt.% manganese (Mn). In another embodiment, the refined aluminum alloy comprises 0.9 wt.% manganese (Mn) or less. In yet another embodiment, the refined aluminum alloy comprises 0.8 wt.% manganese (Mn). In another embodiment, the refined aluminum alloy comprises 0.7 wt.% manganese (Mn) or less. In yet another embodiment, the refined aluminum alloy comprises 0.4 wt.% manganese (Mn).

[0020] As used herein, "3xxx aluminum alloy" refers to wrought aluminum alloys containing manganese (Mn) as the major alloying element, as described in the Aluminum Association's "International Alloy Designations and Chemical Composition Limits for Wrought Aluminum and Wrought Aluminum Alloys (2015)", also known as Teal Sheets.

[0021] Also, the term "3xxx aluminum alloy" or "4xxx aluminum alloy" as used herein refers only to composition and not to any processing, i.e., a 3xxx aluminum alloy or a 4xxx aluminum alloy as used herein is not necessarily a wrought product, but is considered to be an alloy having the composition of a 3xxx or 4xxx aluminum alloy.

[0022] Other alloying additions can also be added to the melt to facilitate the production of suitable aluminum alloy products. For example, (a) they can be added to the melt before removing the iron-containing intermetallic particles, and / or (b) they can be added to the melt after removing the iron-containing intermetallic particles. Alternatively, other alloying additions can be added, for example, before shape casting or casting as an ingot / billet, (c) during remelting of the refined aluminum alloy, or (d) after remelting of the refined aluminum alloy. Alloying additions can also be added to adjust the physical properties (e.g., tensile properties, toughness, corrosion resistance, etc.) of the refined aluminum alloy.

[0023] As used herein, "other alloying additions" or "alloying additions" refers to elements other than aluminum, silicon, iron, and manganese, which may be intentionally added to the melt, for example, to produce a preselected target composition and ultimately a preselected solidified alloy product. Other alloying additions may also be added to facilitate achieving desired physical properties for a preselected target composition. Other alloying additions include chromium (Cr), nickel (Ni), zinc (Zn), titanium (Ti), tin (Sn), strontium (Sr), and the like. In one embodiment, the alloying addition includes at least one of copper (Cu) or magnesium (Mg).

[0024] Components can be manufactured from the refined aluminum alloy. For example, components can be shape cast using the refined aluminum alloy. Components made from the refined aluminum alloy can be used in any suitable application, such as, for example, automotive, aircraft, industrial, or commercial transportation applications. In one embodiment, the refined aluminum alloy component is an automotive component (e.g., a body-in-white (BIW) component, suspension component). In one embodiment, the refined aluminum alloy component is included in an automobile. In one embodiment, the refined aluminum alloy component is an aircraft component. In one embodiment, the refined aluminum alloy component is included in an aircraft. In one embodiment, the refined aluminum alloy component is an industrial component. In one embodiment, the refined aluminum alloy component is a commercial transportation component. In one embodiment, the refined aluminum alloy component is included in a commercial transportation vehicle.

[0025] The use of the tailored intermetallic compound-forming material additives, optionally with other alloying additions, facilitates the production of a predetermined low-Fe aluminum alloy from aluminum alloy scrap. In one embodiment, referring to FIG. 1c, a target refined aluminum alloy composition is preselected (210) for production using the method described herein, where the preselected target composition is either a 3xx cast aluminum alloy, or a 3xxx or 4xxx wrought aluminum alloy. Based on the preselected step and the composition of the aluminum alloy scrap, a specific amount of intermetallic compound-forming material can be added to the aluminum alloy scrap (220). The composition of the aluminum alloy scrap can be determined (221) prior to adding the specific amount of intermetallic compound-forming material and / or other alloying additions. In this manner, the specific amount of intermetallic compound-forming material can be sufficient to achieve removal of iron-containing intermetallic particles (225). The specific amount of intermetallic compound that can be added can be selected using any suitable method. In this regard, the addition of intermetallic compound-forming material can be selected based on experimental results or can be selected based on recycling simulations (e.g., modeling). For example, the database of simulations can be used to calculate the appropriate amount of intermetallics sufficient to achieve removal of the iron-bearing intermetallic particles. After removing the iron-bearing intermetallic particles (225), the methods described herein and / or other alloying additions (222) can be used to produce a refined aluminum alloy having a preselected target composition. It is to be understood that the target composition has a range of compositions. [Brief description of the drawings]

[0026] [Figure 1a] FIG. 1a is an embodiment of producing a refined aluminum alloy.

[0027] [Figure 1b]FIG. 1b is an embodiment for producing a refined aluminum alloy using silicon (Si) and / or manganese (Mn) as intermetallic formers.

[0028] [Figure 1c] FIG. 1c illustrates one embodiment for producing a refined aluminum alloy having a preselected target composition.

[0029] [Figure 2a] FIG. 2a is a photomicrograph of the as-cast MIC6® alloy taken at 300x.

[0030] [Figure 2b] Figure 2b is a photomicrograph of the as-cast alloy MIC6 taken at 3000x.

[0031] [Figure 3a] FIG. 3a is a diagram showing the solidification pathways for the solid fraction of 0 to 1 for the MIC6 alloy of Example 1, plotted using Pandat (registered trademark).

[0032] [Figure 3b] FIG. 3b is a diagram showing the solidification path for the MIC6 alloy of Example 1, plotted by Pandat, for a solid fraction of 0 to 0.2.

[0033] [Figure 4a] FIG. 4a is a diagram showing solidification paths for solid fractions of 0 to 1 for the MIC6 alloy, alloy 1, and alloy 2 of Example 1, plotted by Pandat.

[0034] [Figure 4b] FIG. 4b is a diagram showing solidification paths for the MIC6 alloy, alloy 1, and alloy 2 of Example 1, plotted by Pandat, for solid fractions of 0 to 0.2.

[0035] [Diagram 5]FIG. 5 is a solidification path diagram created by Pandat for solid fractions of 0 to 1, and a plot of the compositions of liquid aluminum, Mn, and Fe in liquid aluminum.

[0036] [Figure 6a] FIG. 6a shows contour plots showing the effect of adding intermetallic compound forming materials Si and Mn for the lowest possible iron content in a recycling simulation.

[0037] [Figure 6b] FIG. 6b is a contour diagram showing the effect of adding intermetallic compound forming materials Si and Mn to the refining temperature range in the recycling simulation.

[0038] [Figure 6c] FIG. 6c is a contour plot showing the effect of alloying additions Cu and Mg for the lowest possible iron content in the recycling simulation.

[0039] [Figure 6d] FIG. 6d is a contour plot showing the effect of alloying additions Cu and Mg on the refining temperature range in the recycling simulation.

[0040] [Figure 7] FIG. 7 is a data table of the recycling simulation of Example 3, showing the solid fraction, liquid aluminum composition, and precipitated phases.

[0041] [Figure 8] FIG. 8 is a data table of the recycling simulation of Example 4, showing the solid fraction, liquid aluminum composition, and precipitated phases.

[0042] [Figure 9] FIG. 9 is a data table of the recycling simulation of Example 5, showing the solid fraction, liquid aluminum composition, and precipitated phases.

[0043] [Figure 10] FIG. 10 is a data table of the recycling simulation of Example 6, showing the solid fraction, liquid aluminum composition, and precipitated phases.

[0044] [Figure 11] FIG. 11 is a data table of the recycling simulation of Example 7, showing the solid fraction, liquid aluminum composition, and precipitated phases. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0045] <Example 1> The recyclable aluminum alloy MIC6 was cast as an ingot. Table 1a shows the typical composition of the aluminum alloy MIC6. [Table la] Photographs of the as-cast aluminum alloy were taken. The 300x micrograph is shown in Figure 2a, and the 3000x micrograph is shown in Figure 2b. As shown, the as-cast aluminum alloy micrograph contains intermetallic phases. The intermetallic phases show Chinese character-like structures, and SEM-EDX analysis reveals that Al 15 (Fe:Mn) 3 S 2 The composition of the intermetallic phase was confirmed by constructing a phase diagram of the composition in Table 1 using Pandat and analyzing the solidification pathway. Figures 3a-3b show the phase diagram constructed by Pandat and the solidification pathway. As shown in Figure 3b, there is a slight refinement temperature range of 2.5°C, but in this refinement temperature range, the solid intermetallic compound Al 15 (Fe:Mn) 3 S 2 does not contain solid aluminum. In principle, the intermetallic compound Al 15 (Fe:Mn) 3 S 2The particles can be separated (e.g., by filtration) from the liquid phase within a temperature range of 2.5° C. However, in practice, the temperature range (2.5° C.) is too small to achieve significant separation.

[0046] The addition of intermetallic silicon and manganese to MIC6 alloy alters the solidification pathway. As shown in Table 1b and Figures 4a-4b, the addition of manganese ("Alloy 1") and a combination of silicon and manganese ("Alloy 2") significantly alters the refining temperature range (ΔT) and the amount of intermetallic Al 15 (Fe:Mn) 3 S 2 The solid fraction increases. [Table lb]

[0047] The solid fraction, iron content, and manganese content in bulk aluminum and the phase change temperature of alloy 2 are shown in Figure 5. As shown in the figure, the intermetallic compound Al 15 (Fe:Mn) 3 S 2 begins to form at about 690°C. At 592°C, solid aluminum (fcc) is in equilibrium with the intermetallic and liquid phases. Thus, from 592°C to 690°C, there is a temperature range of about 97°C where Al 15 (Fe:Mn) 3 S 2 can be separated from the liquid aluminum phase free of solid aluminum. This refining temperature range of about 97° C. is sufficient to separate the intermetallic particles from the bulk liquid aluminum. In one embodiment, the refining temperature range for separating the intermetallic particles from the bulk liquid aluminum is at least 10° C.

[0048] As shown in Figure 5, the intermetallic compound Al was formed by adding an intermetallic compound former. 15 (Fe:Mn) 3 S 2The iron in the bulk aluminum can be reduced by removing the intermetallic particles. As shown, the iron concentration in the aluminum is reduced from 0.53 wt. % to about 0.05 wt. % at the solidification temperature of fcc aluminum (592° C.). However, it is probably not possible to reduce the iron in the bulk aluminum by 0.05 wt. % without removing solid aluminum. In one embodiment, the intermetallic particles can be removed (e.g., by filtration) at a temperature higher than the solidification temperature of aluminum (e.g., 10-20° C. higher), avoiding the removal of solid aluminum.

[0049] <Example 2> Refining of aluminum alloys by adding intermetallic compound formers and removing iron-containing intermetallic compound particles can be performed on a variety of aluminum alloys. This allows the construction of recycling process models for other common aluminum alloy compositions. Thermodynamic simulation software Pandat and aluminum thermodynamic database PanAluminum® were used to construct the process models. Note that intermetallic compound formers were selected for each aluminum alloy composition, as described in more detail below. The mixture of intermetallic compound formers and aluminum alloy provides the total composition for the process simulation. Pandat uses the total composition to determine the minimum concentration of iron and the corresponding refining temperature range (ΔT) for the mixture.

[0050] Intermetallic compound formers were selected for each recycling process. Intermetallic compound formers were selected by a Java computer script in the simulation database with masses of intermetallic compound formers that matched compositions that provided good separation results. In this embodiment, the selection of masses of intermetallic compound formers was based on maximizing ΔT and minimizing iron concentration. The simulation database contained 11,520 simulations, which were performed using each combination of elements and compositions shown in Table 2 below. [Table 2]

[0051] Next, a contour diagram was created using 11,520 simulations. Contour diagrams showing the effect of intermetallic compound formers Mn and Si on the iron concentration and refining temperature range for an aluminum alloy containing 2.25 wt% Cu, 0.7 wt% Mg, and 0.5 wt% Zn are shown in Figures 6a and 6b. As shown, as the Si and Mn contents increase, the iron concentration decreases and the refining temperature range increases. For the illustrated Si and Mn content ranges and the aluminum alloy composition, the iron concentration varies from 0.10 to about 0.70 wt%, and the refining temperature range varies from 20°C to about 100°C. Contour diagrams showing the effect of intermetallic compound formers Cu and Mg on the iron concentration and refining temperature range for an aluminum alloy containing 2.0 wt% Mn, 10.0 wt% Si, and 0.5 wt% Zn are shown in Figures 6c and 6d. As shown, as the Cu and Mg contents increase, the iron concentration decreases and the refining temperature range increases. For the indicated Cu and Mg content ranges and aluminum alloy composition, the iron concentration varies from 0.11 to about 0.14 wt % and the refining temperature range varies from 94°C to about 104°C.

[0052] <Example 3> An alloy having the composition shown in Table 3b ("Alloy 3") was simulated using the simulation procedure of Example 2. The intermetallic compound formers manganese and silicon were added as (1) a manganese master alloy (85 wt% Al and 15 wt% Mn) and (2) pure silicon. The simulation results in the lowest possible iron content of about 0.10 wt% at a temperature of 600.2°C and a refining temperature range of about 77°C. The simulation results show that a final alloy composition with an Fe content of 0.13-0.17 wt% is achieved by filtering at a temperature about 10-20°C above the solidification temperature of aluminum to remove the intermetallic phases. The masses of alloy 3 and the intermetallic compounds are shown in Table 3a. The composition of alloy 3, the composition of the melt (composition of alloy 3 and the total intermetallic compound formers), and the composition of the final melt after refining are shown in Table 3b. The complete data for the recycling simulation is shown in FIG. 7. [Table 3a] [Table 3b]

[0053] <Example 4> A mixture of two alloys ("Alloy 4a" and "Alloy 4b") having the compositions shown in Table 4b was simulated using the simulation procedure of Example 2. Alloy 4a is a representative 6061 aluminum alloy. The intermetallic compound formers manganese and silicon were added as (1) manganese master alloy (85 wt% Al and 15 wt% Mn) and silicon was added as (2) pure silicon. Pure copper was added to raise the copper content in the alloy to about 1.0 wt%. The simulation results show that the lowest possible iron content of about 0.08 wt% is achieved at a temperature of 594.9°C, with a refining temperature range of about 105°C. The simulation results show that a final alloy composition with an Fe content of 0.11-0.14 wt% is achieved by filtering at a temperature about 10-20°C above the solidification temperature of aluminum to remove the intermetallic compound phase. The masses of Alloy 4a, Alloy 4b, Mn master alloy, pure Si, and pure Cu are shown in Table 4a. The compositions of Alloy 4a, Alloy 4b, the melt composition (total composition of Alloy 4a, Alloy 4b, Mn master alloy, pure Si and pure Cu), and the final melt composition after refinement are shown in Table 4b. More complete data from the recycling simulation are shown in Figure 8. [Table 4a] [Table 4b]

[0054] <Example 5> A mixture of two alloys ("Alloy 5a" and "Alloy 5b") with the compositions shown in Table 5b was simulated using the simulation procedure of Example 2. The intermetallic compound formers manganese and silicon were added as (1) a manganese master alloy (85 wt% Al and 15 wt% Mn) and silicon was added as (2) pure silicon. The simulations showed that a temperature of 592.7°C resulted in the lowest possible iron content of about 0.08 wt% and a refining temperature range of about 84°C. The simulations showed that a final alloy composition with an Fe content of 0.10-0.13 wt% was achieved by filtering at a temperature about 10-20°C above the aluminum solidification temperature to remove the intermetallic phase. The masses of Alloy 5a, Alloy 5b, Mn master alloy and pure Si are shown in Table 5a. The compositions of Alloy 5a, Alloy 5b, the melt composition (total composition of Alloy 5a, Alloy 5b, Mn master alloy and pure Si), and the final melt composition after refinement are shown in Table 5b. More complete data from the recycling simulation are shown in Figure 9. [Table 5a] [Table 5b]

[0055] <Example 6> A mixture of two alloys ("Alloy 6a" and "Alloy 6b") with the compositions shown in Table 6b was simulated using the simulation procedure of Example 2. The intermetallic compound former silicon was added as pure silicon. The simulation results in the lowest possible iron content of about 0.10 wt.% at a temperature of 597.9°C, with a refining temperature range of about 67°C. The simulation results show that a final alloy composition with an Fe content of 0.12-0.16 wt.% is achieved by filtering at a temperature about 10-20°C above the aluminum solidification temperature to remove the intermetallic phase. The masses of Alloy 6a, Alloy 6b and pure Si are shown in Table 6a. The compositions of Alloy 6a, Alloy 6b, the melt composition (total composition of Alloy 6a, Alloy 6b and pure Si), and the final melt composition after refining are shown in Table 6b. More complete data from the recycling simulation are shown in Figure 10. [Table 6a] [Table 6b]

[0056] <Example 7> An alloy having the composition shown in Table 7b ("Alloy 7") was simulated using the simulation procedure of Example 2. The intermetallic compound former silicon was added as pure silicon. Pure copper was added to raise the copper content in the alloy to about 1.9 wt%. The simulation results in the lowest possible iron content of about 0.09 wt% at a temperature of about 595.1°C and a refining temperature range of about 100°C. The simulation results show that a final alloy composition with an Fe content of 0.12-0.15 wt% is achieved by filtering at a temperature about 10-20°C above the aluminum solidification temperature to remove the intermetallic phase. The masses of Alloy 7, Mn master alloy, and pure Si are shown in Table 7a. The composition of Alloy 7, the composition of the melt (total composition of Alloy 7, pure silicon, and pure copper), and the composition of the final melt after refining are shown in Table 7b. The complete data for the recycling simulation is shown in Figure 11. [Table 7a]

Table 7b

Claims

1. (a) melting aluminum alloy scrap having an initial iron content of at least 0.20 wt. % iron (Fe), thereby producing a melt; (b) adding to the melt an intermetallic compound forming material comprising silicon (Si) or manganese (Mn) or both Si and Mn; (c) producing iron-containing intermetallic particles in the melt by the adding step (b); (d) removing at least a portion of the iron-containing intermetallic particles from the melt, thereby producing a melt having a reduced iron content; (e) solidifying the low-iron melt thereby producing a refined aluminum alloy from the low-iron melt, The refined aluminum alloy comprises refined iron, the refined iron content being less than the initial iron content.

2. 2. The method of claim 1, wherein the intermetallic compound-forming material comprises silicon, and wherein adding step (b) comprises adding a sufficient amount of silicon to produce an iron-lean melt, said iron-lean melt comprising at least 3 wt. % Si.

3. 3. The method of claim 1 or 2, wherein the refined aluminum alloy is one of a 3xx aluminum cast alloy or a 4xxx wrought aluminum alloy.

4. 4. The method of claim 1, wherein the refined aluminum alloy contains up to 0.35% by weight iron (Fe).

5. 5. The method of claim 1, wherein the refined aluminum alloy contains up to 0.20 wt. % iron (Fe).

6. 6. The method of claim 1, wherein the refined aluminum alloy contains up to 0.15 wt. % iron (Fe).

7. 7. The method of any of claims 1 to 6, wherein the intermetallic compound-forming materials include both silicon and manganese, and the adding step (b) includes adding sufficient silicon and manganese to produce an iron-lean melt, the iron-lean melt including 1.8 wt. % manganese (Mn) or less.

8. 2. The method of claim 1, wherein the refined aluminum alloy is a 3xxx wrought aluminum alloy.

9. The generating step includes:

9. The method of any of claims 1 to 8, comprising: (i) cooling the melt from a first temperature to a second temperature, thereby producing iron-containing intermetallic particles.

10. 10. The method of claim 9, comprising completing the removing step at a second temperature or a temperature less than the second temperature.

11. The method of claim 10 , wherein the removing step comprises at least one of filtering the melt and precipitating the melt.

12. 12. The method of claim 11, wherein removing comprises filtering with a heat resistant filter material.

13. 11. The method of claim 10, wherein the second temperature is at least 10°C above the freezing temperature of fcc aluminum.

14. 14. The method of claim 13, wherein the solidifying step (e) comprises cooling the melt from the second temperature to a temperature below the solidus temperature of the low-iron melt.

15. 15. The method of claim 14, wherein the first temperature is a liquidus temperature, said liquidus temperature being at least 10 degrees Celsius greater than the second temperature.

16. 16. The method of any of claims 1 to 15, including the step of adding alloying additions to the melt.

17. The method of claim 16 including completing the step of adding alloying additions after removing step (d).

18. 20. The method of claim 17, wherein the alloying addition comprises at least one of copper (Cu) and magnesium (Mg).

19. 19. The method of any one of claims 1 to 18, wherein the refined iron content is at least 10% less than the initial iron content.

20. 20. The method of any one of claims 1 to 19, wherein the refined iron content is at least 25% less than the initial iron content.

21. 21. The method of any one of claims 1 to 20, wherein the refined iron content is at least 60% less than the initial iron content.

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