Energy demand reduction of aluminum alloys recycling through friction stir extrusion processes implementation

Aluminum alloys are characterized by high-energy demands for primary production. Recycling is a well-documented strategy to lower the environmental impact of light alloys production. Despite that, conventional recycling processes are still energy-intensive with a low energy efficiency. Also, permanent material losses occur during remelting because of oxidation. Recently, several solid-state recycling approaches have been analyzed; in fact, by avoiding the remelting step both energy and material can be saved and, therefore, the embodied energy of secondary production can be substantially reduced. In this paper, the solid-state approach Friction Stir Extrusion (FSE) is analyzed for aluminum alloys recycling, the primary energy demand of such recycling strategy is quantified. Comparative analyses with both conventional and direct extrusion based processes are developed.