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<p>This study establishes a baseline processing window for commercial-purity-type recycled scrap aluminium produced by stir–squeeze casting. The objective was to optimize the casting parameters of recycled aluminium using a Taguchi L9 orthogonal array and multi-response analysis. Mechanical stirring was applied to homogenize the remelted scrap charge before die filling and pressure-assisted solidification. Four process variables were investigated: squeeze pressure, die preheat temperature, pressure holding duration, and stirring speed, with levels of 50–100&#xa0;MPa, 275–325&#xa0;°C, 20–40&#xa0;s, and 500–600&#xa0;rpm, respectively. The recycled aluminium contained 0.05&#xa0;wt.% Cu.%, Mg 0.05&#xa0;wt.%, Si 0.25&#xa0;wt.%, Fe 0.40&#xa0;wt.%, Mn 0.05&#xa0;wt.%, Zn 0.07&#xa0;wt.%, Ti 0.05&#xa0;wt.%, and Al balance. Ultimate tensile strength, Brinell hardness, compressive strength, fatigue life, and Charpy impact energy were evaluated and analysed using signal-to-noise ratios, ANOVA, and confirmation testing. The selected multi-response condition was 100&#xa0;MPa squeeze pressure, 325&#xa0;°C die preheat temperature, 30&#xa0;s pressure holding duration, and 500&#xa0;rpm stirring speed. Confirmation testing at this setting produced 150.5&#xa0;MPa ultimate tensile strength, 58.1&#xa0;BHN hardness, 373.4&#xa0;MPa compressive strength, 78,400 fatigue cycles, and 76&#xa0;J Charpy impact energy. The results provide a reference condition for pressure-assisted processing of monolithic recycled aluminium and support future innovation involving ultrasonic melt treatment or reinforcement addition.</p>

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Multi-response Optimization of Stir–Squeeze Casting Parameters for Unreinforced Commercial-Purity Recycled Aluminium Scrap

  • 期刊论文

  • 发表日期：

    2026年7月23日

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  • Vignesh Palanivelu,
  • Mukilan Natesan,
  • Ratchagaraja Dhairiyasamy,
  • Subhav Singh

摘要

This study establishes a baseline processing window for commercial-purity-type recycled scrap aluminium produced by stir–squeeze casting. The objective was to optimize the casting parameters of recycled aluminium using a Taguchi L9 orthogonal array and multi-response analysis. Mechanical stirring was applied to homogenize the remelted scrap charge before die filling and pressure-assisted solidification. Four process variables were investigated: squeeze pressure, die preheat temperature, pressure holding duration, and stirring speed, with levels of 50–100 MPa, 275–325 °C, 20–40 s, and 500–600 rpm, respectively. The recycled aluminium contained 0.05 wt.% Cu.%, Mg 0.05 wt.%, Si 0.25 wt.%, Fe 0.40 wt.%, Mn 0.05 wt.%, Zn 0.07 wt.%, Ti 0.05 wt.%, and Al balance. Ultimate tensile strength, Brinell hardness, compressive strength, fatigue life, and Charpy impact energy were evaluated and analysed using signal-to-noise ratios, ANOVA, and confirmation testing. The selected multi-response condition was 100 MPa squeeze pressure, 325 °C die preheat temperature, 30 s pressure holding duration, and 500 rpm stirring speed. Confirmation testing at this setting produced 150.5 MPa ultimate tensile strength, 58.1 BHN hardness, 373.4 MPa compressive strength, 78,400 fatigue cycles, and 76 J Charpy impact energy. The results provide a reference condition for pressure-assisted processing of monolithic recycled aluminium and support future innovation involving ultrasonic melt treatment or reinforcement addition.