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Foundry alloys for high-pressure die cast (HPDCHigh-Pressure Die Casting (HPDC)) structural automotiveAutomotive components have traditionally relied on primary aluminiumAluminium. However, incorporating recycled content is essential to meet the increasing demand and sustainabilitySustainability targets in the automotiveAutomotive sector. This study evaluates two alloys, AlSi10MnMg0.1 and AlSi10MnMg0.3, produced at a primary casthouseCasthouse with 0wt% and 22wt% post-consumer scrapScrap (PCSPost-Consumer Scrap (PCS)): twitch (mixed automotiveAutomotive scrapScrap) or taint tabor (old sheet scrapScrap). The results showed that the recycled content did not affect melt qualityQuality (inclusions), but it raised the Fe and Cu concentration. This did not substantially affect the mechanical propertiesMechanical properties, except for slightly lower bending angles in T6 condition. However, the batch with the highest Cu content exhibited increased corrosion susceptibility. These findings suggest that structural HPDCHigh-Pressure Die Casting (HPDC) alloys with 20wt% PCSPost-Consumer Scrap (PCS) and CO₂ footprints near 3.0 kg CO₂/kg Al are achievable without compromising mechanical integrity, whilst corrosion is more sensitive to impurity levels. More homogeneous scrapScrap streams are recommended to minimise the risks linked to compositional variability.

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Recycling Aluminium Post-Consumer Scrap in a Primary Casthouse into Low-Carbon HPDC Structural Alloys

  • 会议论文

  • 发表日期：

    2026年

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  • Alicia Vallejo-Olivares,
  • Anna Kisko,
  • Jan Tore Gundersen,
  • Martha Indriyati,
  • Are Bergin,
  • Petter Åsholt

摘要

Foundry alloys for high-pressure die cast (HPDCHigh-Pressure Die Casting (HPDC)) structural automotiveAutomotive components have traditionally relied on primary aluminiumAluminium. However, incorporating recycled content is essential to meet the increasing demand and sustainabilitySustainability targets in the automotiveAutomotive sector. This study evaluates two alloys, AlSi10MnMg0.1 and AlSi10MnMg0.3, produced at a primary casthouseCasthouse with 0wt% and 22wt% post-consumer scrapScrap (PCSPost-Consumer Scrap (PCS)): twitch (mixed automotiveAutomotive scrapScrap) or taint tabor (old sheet scrapScrap). The results showed that the recycled content did not affect melt qualityQuality (inclusions), but it raised the Fe and Cu concentration. This did not substantially affect the mechanical propertiesMechanical properties, except for slightly lower bending angles in T6 condition. However, the batch with the highest Cu content exhibited increased corrosion susceptibility. These findings suggest that structural HPDCHigh-Pressure Die Casting (HPDC) alloys with 20wt% PCSPost-Consumer Scrap (PCS) and CO₂ footprints near 3.0 kg CO₂/kg Al are achievable without compromising mechanical integrity, whilst corrosion is more sensitive to impurity levels. More homogeneous scrapScrap streams are recommended to minimise the risks linked to compositional variability.