MATERIALS TESTING FOR RECYCLING
A Study on the Recycling of
Aluminium Alloy 7075 Scrap
Gökhan Özer, Sarp Burgucu, and
Müzeyyen Marsoğlu, Istanbul,
Turkey
The recycling of aluminium scrap has a sig-
nificant impact on economic, energy, envi-
ronmental and resource savings. Com-
pared to the primary aluminium produc-
tion, aluminium recycling has a great
advantage due to its lower production
costs. In order to efficiently recycle metals,
the industry faces various issues such as
scrap sampling, scrap purchasing, metal
recovery (based on recoverable metal in
scrap) and yield (based on total mass of
scrap), production cost and profit margins,
product quality, environmental issues and
regulations [1-3]. 7xxx series Al alloys
have been widely used as structural mate-
rials in aeronautical industries due to their
attractive comprehensive properties, such
as low density, high strength, ductility,
toughness, and resistance to fatigue [3-5].
7xxx series alloys are the most heavily al-
loyed of the wrought aluminium alloys.
They feature 1.5 to 10 wt.-% zinc, depending
on the alloy. 7xxx alloys also have up to 3
wt.-% magnesium, and some feature up to
2.6 wt.-% copper. Heat-treated 7xxx alloys
have the highest strengths of the common
wrought aluminium alloys, with impressive
54 (2012) 3 © Carl Hanser Verlag, München Materials Testing
175
Aluminium and its alloys have recently become an important metal
whose area and amount of usage increase more and more, due to their
mechanical properties, recycling ability, and penetrability. If it is con-
sidered that the bauxite, which is the raw material of aluminium is rare
on earth, and also the area and amount of aluminium usage increases
over time, the importance of aluminium recycling goes up. aluminium
recycling has become crucial by means of both, the potential of the
scrap’s dependant increase on usage and the primary aluminium pro-
duction, as it is providing energy and cost savings. 7xxx grades of scrap
are collected with other scrap of aluminium alloys in one turn and recy-
cled all together. As the regain of these alloys is not done by isolation
oft he various grades, the finally recycled ingots result in lower grades.
High value aluminium scrap is regrettably not recovered, as it was
anticipated. This study is dealing with 7075 aluminium alloys originated
from discharged blow molding tools and the rest piece cuttings of blocks
and plates. The material has been subjected to an induction furnace,
and has been remelted into small ingots and hardened according to
7075 aluminium alloy parameters (hardening aluminium tooling).
toughness levels. As with the 2xxx alloys, 7xxx grades of scrap are collected with
the lower corrosion resistance of such mate- other scrap of aluminium alloys in one turn
rials usually ends up by being painted or and recycled all together. As the regain of
coated when they are put into service. His- these alloys is not done by isolation oft he
torically, their greatest use has been in the grades, the finally recycled ingots result in
aircraft industry, but they have also found lower grades [5-8]. In this study, particu-
use in transport applications. Their zinc and larly 7075 aluminium scrap recyling has
copper content make the 7xxx alloys diffi- been investigated.
cult to recycle into anything except 7xxx al-
loys or some casting alloys. The 7xxx cast Experimental Procedures
alloys specifications require 2.7 to 8.0 wt.-% and Results
zinc, similar to their 7xxx wrought counter-
parts. Magnesium (0.5 to 2.0 wt.-%) is pre- Aluminium products produced by using
sent in many of these alloys, and chromium 7075 aluminium alloys (Table 1) and ob-
(0.2 to 0.6 wt.-%) sometimes exists as well. tained from worn heading dies and cutting
They have better corrosion resistance than material scrap sold as plates or blocks have
other cast alloys and develop high strength been used for industrial melting in an in-
through natural aging, eliminating the need duction furnace and subsequent casting of
for heat treatment. a metal mold. The obtained casting pieces
Sample name Fe Si Cr Ni Al Cu Mg Pb Ti Zn
1 0.081 0.459 - 0.057 89.29 2.62 1.45 0.015 0.025 5.90
2 0.109 0.125 - 0.019 88.95 2.93 1.57 0.016 0.027 6.15
3 0.193 0.178 0.013 0.022 89.28 2.26 1.80 0.015 0.016 6.13
Table1. Results of spectral analysis of aluminium 7075 samples and scrap taken from heading dies (wt.-%)
176 MATERIALS TESTING FOR RECYCLING

Casting No Amount of charge (g) Casting Temperature (°C ) Weight (g) were subjected to heat treatments to obtain
again 7075 aluminium alloys (so-called
1.1 80.25 770 °C 76.10
hard aluminium).
1.2 80.60 780 °C 70.90
1.3 70.80 730 °C 61.10 Castings
Table 2. Amount of the charges, casting temperature, and final weight
7075 aluminium alloy scraps were melted
in a graphite crucible in an induction fur-
Sample name Fe Si Cr Ni Al Cu Mg Pb Ti Zn nace and 18 x 35 x 65 mm samples were
1.A 0.054 0.006 - 0.017 90.55 2.20 1.32 0.016 0.028 5.70 obtained from such castings. The produc-
tion procedures are listed in Table 2, and the
1.B 0.081 0.020 - 0.015 89.78 2.51 1.44 0.016 0.027 6.01
chemical composition is given in Table 3.
1.C 0.163 0.059 0.013 0.017 89.84 1.87 1.73 0.015 0.015 6.17 In the castings, although analyses were
so close to 7075 analysis, losses were ob-
Table 3. Chemical composition of the casting pieces (wt.-%)
served especially in the amounts of Cu and
Mg. It was thus the goal to raise the amount
Sample name Fe Si Cr Ni Al Cu Mg Pb Ti Zn of Cu and Mg by adding flux by various
2.A (0 wt.-wt.-% Flux) 0.145 0.036 0.014 0.018 89.79 2.13 1.34 0.017 0.015 6.38 amounts (0, 1, 2, 3, 5, 10, and 15 wt.-%) in
the following castings, as given in Figure 2.
2.B (1 wt.-% Flux) 0.132 0.036 0.010 0.015 89.60 2.36 1.54 0.015 0.022 6.16
As flux, ECREMAL N 14 S which prevents
2.C (2 wt.-% Flux) 0.133 0.037 0.009 0.015 89.64 2.37 1.47 0.015 0.022 6.18 oxidation in the aluminium cast was used.
2.D (3 wt.-% Flux) 0.126 0.034 0.008 0.015 89.82 2.34 1.42 0.015 0.023 6.10 When comparing the Castings 1 and 2, it
2.E ( 5 wt.-% Flux) 0.072 0.005 - 0.017 90.31 2.28 0.956 0.018 0.021 6.22 was seen that although flux has a positive
effect on Zn, it has negative effect on Cu
2.F (10 wt.-% Flux ) 0.062 0.001 - 0.017 90.26 2.34 0.946 0.018 0.022 6.23
and Mg, i. e. Mg and Cu get through the
2.G ( 15 wt.-% Flux ) 0.160 0.117 0.017 0.020 90.05 2.07 1.14 0.018 0.014 6.29 flux. Moreover, when the cast without flux
obtained from Casting 2 and Casting 1 are
Table 4. Chemical analysis of the casting samples 2.A, 2.B, 2.C 2.D, 2.E, 2.F, and 2.G (wt.-%)
compared, it was seen that although both
are in the same condition, a difference was
Sample name Mg % Amounts of charge (g) Casting Temperature (°C) Casting sample (g) observed in the analysis especially in the
3.A 1 59g scrap + 0.59 Mg 710 °C 51.80 sense of Zn.
In order to prevent the loss of Mg caused
3.B 2 51g scrap + 1.02 Mg 770 °C 45.59
by oxidation that occurs during melting
3.C 3 52,3g scrap + 1.57g Mg 660 °C 50.74 and to increase the rate of Mg, pure Mg was
added in the rate of 1, 2 and 3 wt.-%. In the
Table 5. Amount of charges, casting temperature and weight of pieces obtained as a result of casting
the samples 3.A, 3.B and 3.C Table 5 and 6, Mg rates added to the 7075
aluminium scraps, charge rates, and heat
of casting are given.
Sample name Fe Si Ni Al Cu Mg Pb Ti Zn After casting, the chemical analysis was
3.A 0.076 0.028 0.017 89.51 2.56 1.68 0.017 0.022 5.98 carried out with a Hilger Anaytical Polvac
3.B 0.043 - 0.015 88.02 2.72 2.70 0.017 0.020 6.36 Optical Emission Spectrometer. Analysis
results are given in Table 6. By such re-
3.C 0.046 0.003 0.014 86.73 2.83 3.68 0.017 0.019 6.55
sults, it was seen that a Mg addition reply
Table 6. Chemical analysis of the samples 3.A, 3.B and 3.C (wt.-%) is successful, an even higher increase was

Figure 2. Casting efficiency and casting temperature as a result of casting

Figure 1. Die heading sample of samples with 0, 1, 2, 3, 5, 10, and 15 wt.-% flux included

54 (2012) 3
 MATERIALS TESTING FOR RECYCLING 177

observed of adding Zn together with Mg. Sample no Mg % Amounts of charges (g) Casting temperature (°C) Casting sample (g)
Considering the results of the Mg addition,
4.1 1.5 61.33g scrap + 0.92 Mg 720 °C 57.37
it becomes obvious that a 1.5 wt.-% Mg ad-
4.2 1.5 59.33 scrap + 0.89 Mg 750 °C 56.53
dition would result in a good chemical com-
position. 4.3 1.5 62g scrap + 0.93g Mg 690 °C 58.93
Adding of 1.5 wt.-% Mg to the castings
Table 7. Amount of charges, casting temperature, and weight of pieces as a result of 1.5 wt.-% Mg
was done three times. The respective data addition in the samples 4.1, 4.2, 4.3
are listed in Table 7 and the chemical anal-
ysis is given Table 8. As a result of the
analysis, it was observed that the amount
of Mg increases due to the 1.5 wt.-% Mg ad-
dition, besides there is a decrease in the Sample No Mg Fe Si Cr Ni Al Cu Mg Pb Ti Zn
amount of Zn. 4.1 1.5 Mg 0.082 0.003 - 0.013 85.90 2.67 2,84 0.015 0.022 8,35>
When the analysis differences between 4.2 1.5 Mg 0.116 0.009 0.001 0.014 85.81 2.57 2,86 0.015 0.025 8,47>
the same charges are evaluated, consider-
4.3 1.5 Mg 0.108 0.009 0.001 0.014 85.89 2.68 2,87 0.015 0.015 8,49>
ing the fact that the amount of the charges
prepared for casting is different, rapid cool- Table 8. Chemical analysis of the samples 4.1, 4.2, 4.3 (wt.-%)
ing during casting caused segregation pro-
cesses. For this reason, two millimeter
metal was removed by milling over the
Casting 1 samples and subsequently, the
Sample name Fe Si Cr Al Cu Mg Pb Ti Zn
samples were subjected to the chemical
analysis another time. As a result of this F 1.1 0.057 - - 90.07 2.05 1.81 0.016 0.052 5.85
analysis, it turned out that the chemical F 1.2 0.085 0.002 - 89.17 2.46 1.91 0.017 0.052 6.20
composition of the aluminium 7075 alloy
was achieved. For confirmation, in Table 9, F 1.3 0.163 0.061 0.032 89.36 1.74 2.18 0.016 0.029 6.32
the chemical analyses of the two millime-
Table 9. Chemical analysis (wt.-%) of the casting samples 1.1, 1.2, and 1.3 with two millimeter metal
ter milled casting samples 1.1, 1.2, and 1.3 removal by milling
casting is given.
The aluminium 7075 alloy cast samples
obtained by milling were subjected to solu-
tion heat treatment by using a respective
After casting HV After solution treatment HV After ageing HV
furnace. After the samples were heated for
30 minutes at 465 °C and were kept at this 58 86.1 155
temperature for two hours and afterwards 60 90.4 149
cooled in water, they were subjected to ar- 60 89.2 152
tificial ageing for two hours at 121 °C. Af-
ter each process, the hardness of the sam- Table 10. Hardness values of the aluminium alloy 7075 which was heated for 30 minutes at 465 °C
ples was measured with a Struers FM 700 and kept at this temperature for two hours and was then cooled in water, afterwards artificial ageing
hardness measurement device. Hardness was applied for two hours at 121 °C (HV – 500 gf/12 s)
values of the samples are listed in Table 10,
the respective DSC graphic of the sample is
given in the Figures 3 and 4.
The curves show a peak at 225 °C and
470 °C. It was understood that for this cast-
ing sample, following annealing after solu-
tion heat treatment at 225 °C and 470 °C,
the highest hardness values would be at-
tained as a result of the hardening and age-
ing processes.

Conclusions

The following conclusions can be drawn

from the present study:

1. Aluminium 7075 alloy scraps can be re-

produced by casting after a respective
melting process.
2. Flux or alloy element additions are not
required in the melting process. Figure 3. Results of DSC analysis carried out at 10 °C/min in Ar atmosphere up to 600 °C

54 (2012) 3
178 MATERIALS TESTING FOR RECYCLING

3. No significant change in the chemical
composition after casting can be observed.
4. In order to reduce the segregation to
a minimum after casting, slow cooling
in a respective environment is re-
quired.
5. After casting and respective heat treat-
ment, hardness values between 150 and
160 HV are achieved. Such hardness value
are very close to the hardness of commer-
cially available aluminium 7075 alloys.
6. For the aforementioned reasons, by us-
ing qualified scraps it is possible to pro-
duce and recycle the respective alumin-
ium 7075 alloy.

Acknowledgement

The authors wish to acknowledge Ozgul Ke-

les from Istanbul Technical University and
Mustafa Cigdem fromYildiz Technical Uni-
versity Metallurgical and Materials Engi-
neering Department for their contributions.

References

1 J. Li, Z. Peng, C. Li, Z. Jia, W. Chen, Z. Zheng:

Mechanical properties, corrosion behaviors
and microstructures of 7075 aluminium alloy
with various aging treatments, Trans. Nonfer-
rous Met. Soc. China. 18 (2008), pp. 755-762
2 M. E. Schlesinger: Alumium Recyling, CRC Press,
University of Missouri-Rolla, MO, U.S.A., (2007)
3 J. A. S. Tenorio, D. C. R. Espinosa: Effect of salt/
Figure 4. Results of DSC analysis result carried out at 10 °C/min in Ar atmosphere up to 600 °C, oxide interaction on the process of aluminium
derivation of the red DSC curve recycling, Journal of Light Metals 2 (2002),
pp. 89-93
4 H. Amini, H. A. Mashhadi, A. Moloodi,
Abstract M. Golestanipour, E. Z. V. Karimi: Recycling of
aluminium alloy turning scrap via cold press-
ing and melting with salt flux, Journal of Mate-
Eine Recyclingstudie für Schrott aus der Aluminiumlegierung 7075. rials Processing Technology 209 (2009),
Aluminium und seine Legierungen sind in den letzten Jahren aufgrund pp. 3138-3142
5 Y. Xiao, M. A. Reuter: Recycling of distributed
ihrer mechanischen Eigenschaften, ihrer Recyclingfähigkeit und ihrer
aluminium turning scrap, Minerals Engineer-
Durchlässigkeit immer bedeutendere metallische Werkstoffe geworden. ing 15 (2002), pp. 963-970
Unter Berücksichtigung, dass Bauxit als Rohmaterial selten auf der Erde 6 O. Majidi, S. G. Shabestari, M. R. Aboutalebi:
Study of fluxing temperature in molten alu-
vorkommt und der Verbrauch mit der Zeit steigt, wächst die Bedeutung minium refining process, Journal of Materials
des Recyclings von Aluminium. Aluminiumrecycling, zumal es Energie- Processing Technology 182 (2007), pp. 450-455
7 T. A. Utigard, K. Friesen, R. R. Roy, J. Lim,
und Kosteneinsparungen ermöglicht, ist sowohl für die schrottabhängi- A. Silny, C. Dupuis: The properties and uses
gen Verwendungspotentiale und die PrimärAluminiumproduktion glei- of fluxes in molten aluminium processing,
chermaßen bedeutend geworden. Die 7xxxx Schrottlegierungen werden JOM 11 (1998), pp. 38-43
8 S. Burgucu: The Production and Characteriza-
in einem Arbeitsgang mit dem Schrott aus anderen Aluminiumlegierun- tion aluminium Alloys According to 7075
gen gesammelt und recycled. Da die Wiedergewinnung dieser Legierun- Standard, Master Thesis, Yildiz Technical
University, İstanbul (2011)
gen nicht nach isolierten Legierungstypen erfolgt, bestehen die schließ-
lich recycelten Barren aus niedrigeren Graden. Hochwertiges Aluminium The Authors of This Contribution
wird bedauerlicherweise nicht wie vorgesehen wiedergewonnen. Dieser
Gökhan Özer, born in 1978, is a research assis-
Beitrag behandelt Material, das entladenen Blasformteilwerkzeugen so- tant at the Yildiz Technical University since
wie Reststücken aus Schnitten von Blöcken und Platten entstammt. Das 2002. He is also co-researcher at the Balkan Cen-
tre of Advanced Casting Technologies (BCACT).
Material wurde in einem Induktionsofen wieder in kleinen Gussstücken Presently, he is PhD student in the casting of
zerschmolzen und entsprechend der üblichen Parameter für die Alumini- non-ferrrous metals.
Sarp Burgucu, born in 1977, is sales manager
umlegierung 7075 gehärtet (Aushärtung von Werkzeugen aus Alumi- of Quantum tool steels. Presently, he is PhD stu-
nium). dent in the field of casting of non-ferrrous metals.
Prof. Müzeyyen Marsoğlu graduated from
İstanbul University in 1971 and is working ath
the Yildiz Technical University in the Department
You will find the article and additional material by entering the document number MP110309
for Metal and Materials Science Engineering. She
on our website at www.materialstesting.de
is an expert at metallography, non-metal materi-
als and material science.

54 (2012) 3