A novel approach to enhance mechanical properties during recycling of aluminum alloy scrap through friction stir consolidation

Solid state recycling (SSR) is a new approach for making metals more efficient with respect to remelting-based approaches. Friction stir consolidation (FSC) solid-state process that employed recycle metallic scraps. Until now, single-step FSC was applied recycled metal chips. During the approach, critical processes parameters, especially processing time and rotational speed, are considered vital control quality mechanical properties of billet. However, effectiveness parameters highly restricted by challenging masses chips machine competency. The present study first highlights issues process, such as unconsolidated billet poor at bottom part, i.e., far away from stirring action. Then, time, three different two-step methods were introduced approaches overcome existing challenges method. these evaluated through Vickers hardness measurements, microstructure analysis. results showed successfully led fully consolidated considerably improved properties.