A recycling route for e-waste and aluminium scrap to produce A2xxx and A3xx Al alloys

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Abstract Electronic waste (e-waste) generation is significantly escalating, while traditional recycling methods, failing to meet sustainability criteria, are still used. The implementation of sustainability requirements calling for recycling will not be achieved unless intensive research is conducted for mitigating and tolerating the presence of accumulating tramp elements in the recycled alloys and even revising the existing standard specifications. This study explores an innovative approach to recycling electronic waste (e-waste) by integrating it with aluminum scrap through conventional melting techniques to produce high-performance industrial alloys aiming to develop novel aluminum alloys with enhanced properties suitable for various industrial applications. The experimental process involved combines pulverized e-waste in powder form with aluminum scrap to create alloys compatible with the 2xxx and 3xx series aluminum alloys. Characterization, including microstructure analysis, phase identification, thermodynamic modeling, and mechanical strength of the developed samples confirmed the potential of these alloys to meet the requirements of the 2xxx and 3xx series. The findings highlight the feasibility of using e-waste as a sustainable alloying source, offering a promising solution to reduce environmental impact while conserving natural resources. This research lays the groundwork for further exploration of the heat treatment and mechanical properties and broader industrial applications of these introduced alloys. Graphical abstract

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