Dimos Paraskevas

Spark Plasma Sintering As a Solid-State Recycling Technique: The Case of Aluminum Alloy Scrap Consolidation

Recently, “meltless” recycling techniques have been presented for the light metals category, targeting both energy and material savings by bypassing the final recycling step of remelting. In this context, the use of spark plasma sintering (SPS) is proposed in this paper as a novel solid-state recycling technique. The objective is two-fold: (I) to prove the technical feasibility of this approach; and (II) to characterize the recycled samples. Aluminum (Al) alloy scrap was selected to demonstrate the SPS effectiveness in producing fully-dense samples. For this purpose, Al alloy scrap in the form of machining chips was cold pre-compacted and sintered bellow the solidus temperature at 490 °C, under elevated pressure of 200 MPa. The dynamic scrap compaction, combined with electric current-based joule heating, achieved partial fracture of the stable surface oxides, desorption of the entrapped gases and activated the metallic surfaces, resulting in efficient solid-state chip welding eliminating residual porosity. The microhardness, the texture, the mechanical properties, the microstructure and the density of the recycled specimens have been investigated. An X-ray computed tomography (CT) analysis confirmed the density measurements, revealing a void-less bulk material with homogeneously distributed intermetallic compounds and oxides. The oxide content of the chips incorporated within the recycled material slightly increases its elastic properties. Finally, a thermal distribution simulation of the process in different segments illustrates the improved energy efficiency of this approach.

Solid State Recycling of Aluminium Sheet Scrap by Means of Spark Plasma Sintering

Various solid state or ‘meltless’ recycling techniques have recently been developed for light metal scrap in form of chips. Main objective of all approaches is to bypass the need for remelting in order to reduce the overall required energy, and to avoid the material losses that occur during this step. Within this paper, the use of Spark Plasma Sintering (SPS) is proposed as a novel solid state recycling/welding technique for sheet metal scrap. Aluminium 5182 alloy scrap, derived from sheet metal, was successfully consolidated into a fully dense billet via SPS. The use of pulsed electric current heating, in temperatures well below the alloy melting point, combined with mechanical pressure, enchased the densification process resulting into a void-less material. The recycled SPS sample was fully densified and microstructural investigation has been performed in order to confirm effective oxide film breakage. The results illustrate the effectiveness of SPS in aluminium scrap consolidation, also in form of sheet scrap, providing additional means in solid state recycling. The involved mechanisms that contribute to oxide film fracture and scrap consolidation in SPS are being discussed.Keywords: Aluminium, recycling, spark plasma sintering (SPS)

Sustainable Metal Management and Recycling Loops: Life Cycle Assessment for Aluminium Recycling Strategies

The benefit of knowing the exact chemical composition of metal scrap plays a significant role from metallurgical point of view in recycling processes. Thus, the focus of this paper is to identify opportunities for more efficient scrap management, in order to minimize quality loses and primary material consumption during recycling. By moving to compositionally closer recycling loops, higher recycling values by reducing the need for primary metal and alloying elements addition, can be achieved. A Life Cycle Assessment (LCA) was performed, focusing on aluminium scrap, in order to validate, estimate and compare the environmental impact of different recycling options and the effect of scrap separation strategies. Furthermore, a metric to compare the ‘quality’ in terms of recyclability of the various metal flows is proposed.

Solid state recycling of aluminium alloys via a porthole die hot extrusion process: Scaling up to production

Whereas industrial symbiosis has led to increased energy and resource efficiency in process industries, this concept has not yet been applied in discrete product manufacturing. Metal scrap is first conventionally recycled, for which substantial energy and resource efficiency losses have been reported. Recent research has however proven the feasibility of ‘meltless’ recycling of light metal scrap, yielding a first glimpse of potential industrial symbiosis. Various solid state recycling techniques (such as recycling via hot extrusion or Spark Plasma Sintering) have been proposed for scrap consolidation directly into bulk products or semis by physical disruption and dispersion of the oxide surface film by imposing significant plastic and shear strain. Solid State Recycling (SSR) methods can omit substantial material losses as they bypass the metallurgical recycling step. In this context the case of direct production of bulk aluminium profiles via hot extrusion at industrial scale is demonstrated within this paper. The extrusion tests were performed directly into the production line, highlighting the scaling up potentials and the industrial relevance of this research. A significant amount of machining chips were collected, chemically cleaned and cold compacted into chip based billets with ∼80% relative density. Afterwards the scrap consolidation was achieved by imposing significant plastic and shear deformation into the material during hot extrusion through a modified 2-porthole extrusion die-set. The production process sequence along with microstructural investigations and mechanical properties comparison of the cast based profile used as reference versus the chip based profile are presented.Whereas industrial symbiosis has led to increased energy and resource efficiency in process industries, this concept has not yet been applied in discrete product manufacturing. Metal scrap is first conventionally recycled, for which substantial energy and resource efficiency losses have been reported. Recent research has however proven the feasibility of ‘meltless’ recycling of light metal scrap, yielding a first glimpse of potential industrial symbiosis. Various solid state recycling techniques (such as recycling via hot extrusion or Spark Plasma Sintering) have been proposed for scrap consolidation directly into bulk products or semis by physical disruption and dispersion of the oxide surface film by imposing significant plastic and shear strain. Solid State Recycling (SSR) methods can omit substantial material losses as they bypass the metallurgical recycling step. In this context the case of direct production of bulk aluminium profiles via hot extrusion at industrial scale is demonstrated within this ...

Complex deformation routes for direct recycling aluminium alloy scrap via industrial hot extrusion

This paper presents the final results of an industrial project, aiming for direct hot extrusion of wrought aluminium alloy scrap at an industrial scale. Two types of complex deformation/extrusion routes were tested for the production of the same profile, starting from AA6060 scrap in form of machining chips. More specifically scrap-based billets were extruded through: a 2-porthole and a 4-porthole die-set, modified for enhanced scrap consolidation and grain refinement. For comparison reasons, cast billets of the same alloy were extruded through the modified 2-porthole die set. The tensile testing results as well as microstructural investigations show that the 4-porthole extrusion route further improves scrap consolidation compared to the 2-porthole die output. The successful implementation of solid state recycling, directly at industrial level, indicates the technological readiness level of this research.This paper presents the final results of an industrial project, aiming for direct hot extrusion of wrought aluminium alloy scrap at an industrial scale. Two types of complex deformation/extrusion routes were tested for the production of the same profile, starting from AA6060 scrap in form of machining chips. More specifically scrap-based billets were extruded through: a 2-porthole and a 4-porthole die-set, modified for enhanced scrap consolidation and grain refinement. For comparison reasons, cast billets of the same alloy were extruded through the modified 2-porthole die set. The tensile testing results as well as microstructural investigations show that the 4-porthole extrusion route further improves scrap consolidation compared to the 2-porthole die output. The successful implementation of solid state recycling, directly at industrial level, indicates the technological readiness level of this research.

Incorporating denitrification-decomposition method to estimate field emissions for Life Cycle Assessment

This study focuses on a detailed Life Cycle Assessment (LCA) for flax cultivation in Northern France. Nitrogen related field emissions are derived both from a process-oriented DeNitrification-DeComposition (DNDC) method and the generic Intergovernmental Panel on Climate Change (IPCC) method. Since the IPCC method is synthesised from field measurements at sites with various soil types, climate conditions, and crops, it contains significant uncertainties. In contrast, the outputs from the DNDC method are considered as more site specific as it is built according to complex models of soil science. As it is demonstrated in this paper the emission factors from the DNDC method and the recommended values from the IPCC method exhibit significant variations for the case of flax cultivation. The DNDC based emission factor for direct N2O emission, which is a strong greenhouse gas, is 0.25-0.5%, significantly lower than the recommend 1% level derived from the IPCC method. The DNDC method leads to a reduction of 17% in the impact category of climate change per kg retted flax straw production from the level obtained from the IPCC method. Much higher reductions are recorded for particulate matter formation, terrestrial acidification, and marine eutrophication impact categories. Meanwhile, based on the DNDC and IPCC methods, a comparative LCA per kg flax straw is presented. For both methods sensitivity analysis as well as comparison of uncertainties parameterisation of the N2O estimates via Monte-Carlo analysis are performed. The DNDC method incorporates more relevant field emissions from the agricultural life cycle phase, which can also improve the quality of the Life Cycle Inventory as well as allow more precise uncertainty calibration in the LCA inventory.