Solid state recycling of recyclable aluminum wastes with in-process microstructure control

Aiming for actual dematerialization, mass flow must be optimized to make full use of the recyclable materials as input and to reduce total amount of wastes. Since the material efficiency is strongly dependent on their adaptivity to the design demand for recycled products, an effective recycling process must accompany the advanced materials processing and manufacturing to improve their original properties to the level above the demand. In the present paper, the light-mass non-ferrous metallic alloys such as aluminum alloys are targeted, to utilize their bulk wastes, which are often ejected from the electric parts or members, as an input material, and to aim for their reuse as an automotive part. Dense, high-strengthened aluminum alloy compact, or, green materials are handled in the present forming and manufacturing up to the final net-shape formation of products by sinter-forging. Selection of reused materials and in-process improvement of their properties are essential keys in this barrier-free processing. Possibility to replace the conventional processing with this barrier-free process lies in: (1) Reduction of in-process energy and mass consumption, (2) Flexibility to yield various kinds of products without any realignment of processes, and (3) Adaptive in-process material modification to design for products in practical use.