EXTRUSION FEEDSTOCK AND PRODUCT THEREOF INCLUDING EXTRUDABLE ALUMINUM SCRAP

Abstract

A feedstock may include at least 1 wt % of aluminum scrap composition comprising: an extrudable floated fragmentizer aluminum scrap composition, an extrudable fragmentizer aluminum scrap composition, an extrudable secondary aluminum scrap composition; or a mixture of at least two thereof. A feedstock may include at least 0.01 wt % of an alloying element composition at least partially intermixed relative to the aluminum scrap composition, the alloying element composition comprising: silicon, copper, iron, magnesium, chromium, manganese, zinc, oxygen; a rare earth element, or a mixture of at least two thereof.

Description

BACKGROUND

The recycling of aluminum scrap can be important for environmental sustainability and economic efficiency. However, the variability in the composition of aluminum scrap, particularly with respect to impurities, poses challenges in producing high-quality aluminum products suitable for demanding applications. Traditional methods of recycling aluminum scrap can involve complex and costly processes to remove impurities and achieve a homogeneous material, or can involve diluting the impurities with virgin aluminum which can nullify much of the environmental and economic benefits of recycling scrap aluminum.

SUMMARY

In some aspects, the techniques described herein relate to an extrusion feedstock including: at least 1 wt % of aluminum scrap composition including: an extrudable floated fragmentizer aluminum scrap composition; an extrudable fragmentizer aluminum scrap composition; an extrudable secondary aluminum scrap composition; or a mixture of at least two thereof; and at least 0.01 wt % of an alloying element composition at least partially intermixed relative to the aluminum scrap composition, the alloying element composition including: silicon; copper; iron; magnesium; chromium; manganese; zinc; oxygen; rare earth elements; or a mixture of at least two thereof.

In some aspects, the techniques described herein relate to a method of forming a high-performance alloy, the method including: using a shear assisted extrusion device, providing relative rotation between an extrusion die face and a feedstock; applying a relative axial translating force between the extrusion die face and the feedstock sufficient to heat and plasticize, and mix the feedstock at an interface between the feedstock and the extrusion die face to form an alloy that is extruded through an aperture of the die; wherein, the feedstock includes: at least 1 wt % of aluminum scrap composition including: an extrudable floated fragmentizer aluminum scrap composition; an extrudable fragmentizer aluminum scrap composition; an extrudable secondary aluminum scrap composition; or a mixture of at least two thereof; and at least 0.01 wt % of an alloying element composition at least partially intermixed relative to the aluminum scrap composition, the alloying element composition including: silicon; copper; iron; magnesium; chromium; manganese; zinc; oxygen; rare earth elements: or a mixture of at least two thereof

In some aspects, the techniques described herein relate to a high-performance alloy, including an extruded product of feedstock including: at least 1 wt % of aluminum scrap composition including: an extrudable floated fragmentizer aluminum scrap composition; an extrudable fragmentizer aluminum scrap composition; an extrudable secondary aluminum scrap composition; or a mixture of at least two thereof; and at least 0.01 wt % of an alloying element composition at least partially intermixed relative to the aluminum scrap composition, the alloying element composition including: silicon; copper; iron; magnesium; chromium; manganese; zinc; oxygen; rare earth elements: or a mixture of at least two thereof.

BRIEF DESCRIPTION OF THE FIGURES

The drawings illustrate generally, by way of example, but not by way of limitation, various aspects of the present disclosure.

FIG. 1 is a schematic view example of portions of a Shear Assisted Processing and Extrusion (ShAPE) device.

FIG. 2 is another schematic view of an example of portions of the ShAPE device.

FIG. 3 shows a schematic view of portions of a ShAPE device using a rotation tool.

FIG. 4 is a XRD graph showing the chemical constituted of the recycled product and upcycled product.

FIG. 5 is an image showing the microstructure in the upcycled product.

FIG. 6A is a graph showing the standard hardness values of the recycled product.

FIG. 6B is a graph showing the standard hardness of the upcycled product.

FIG. 7 is a graph showing the respective Vickers hardness values of the upcycled and recycled product relative to the center of the respective extruded wire.

FIG. 8 is a graph showing respective hardness values of a reference recycled aluminum AA6063, a recycled aluminum AA6063 extruded with ShAPE, a reference aluminum AA7075, and an upcycled aluminum 7075 using ShAPE.

FIG. 9 is a graph showing the stress values of a reference recycled aluminum AA6063, a recycled aluminum AA6063 extruded with ShAPE, a reference aluminum AA7075, and an upcycled aluminum 7075 using ShAPE.

FIG. 10 is a graph showing respective hardness values of a reference recycled aluminum AA6063, a recycled aluminum AA6063 extruded with ShAPE, a reference aluminum AA7075, and an upcycled aluminum 7075 using ShAPE.

FIG. 11 is a graph showing the yield strength values of a reference recycled aluminum AA6063, a recycled aluminum AA6063 extruded with ShAPE, a reference aluminum AA7075, and an upcycled aluminum 7075 using ShAPE.

FIG. 12 is a graph showing the tensile stress values of a reference recycled aluminum AA6063, a recycled aluminum AA6063 extruded with ShAPE, a reference aluminum AA7075, and an upcycled aluminum 7075 using ShAPE.

FIG. 13 is a graph showing the elongation before break values of a reference recycled aluminum AA6063, a recycled aluminum AA6063 extruded with ShAPE, a reference aluminum AA7075, and an upcycled aluminum 7075 using ShAPE.

DETAILED DESCRIPTION

Reference will now be made in detail to certain aspects of the disclosed subject matter, examples of which are illustrated in part in the accompanying drawings. While the disclosed subject matter will be described in conjunction with the enumerated claims, it will be understood that the exemplified subject matter is not intended to limit the claims to the disclosed subject matter.

The present disclosure relates to an extrusion feedstock that includes various aluminum scrap compositions and mixtures of alloying elements that serve to upcycle the aluminum scrap. Examples of suitable aluminum scrap compositions include floated fragmentizer aluminum scrap, fragmentizer aluminum scrap, secondary aluminum scrap, or a mixture of at least two thereof. With specific reference to floated fragmentizer aluminum scrap and fragmentizer aluminum scrap, those compositions may include with impurities that may otherwise be considered in excess of acceptable levels, and methods for making and using such feedstock to produce extruded aluminum products with improved mechanical properties (e.g., a high-performance alloy). A high-performance alloy can be generally understood to be an alloy having a higher yield strength, ultimate tensile strength, or both than a conventional AA 6xxx series aluminum alloy. The disclosed subject matter provides a cost-effective and potentially environmentally friendly approach to recycling aluminum scrap by utilizing a shear assisted extrusion process that allows for an upcycled product to be formed despite the presences of impurities in the feedstock.

Various aspects of the present disclosure relate to extrusion feedstocks and extruded products including an extrudable floated fragmentizer aluminum scrap composition. As an example, the extrudable floated fragmentizer aluminum scrap composition can be known under the Institute of Scrap Recycling Industries (ISRI) code TWITCH.

As generally understood, the floated fragmentizer aluminum scrap composition will not contain more than a total 2% maximum of a non-metallic, of which no more than 1% will be rubber and/or plastics. The extrudable floated fragmentizer aluminum scrap composition is substantially free of excessively oxidized material, air bag canisters, and/or any sealed or pressurized items. Furthermore, the extrudable floated fragmentizer aluminum scrap composition is substantially free of cardboard, thermo break contaminants; venetian blinds, castings, hair wire, screen wire, radiator shells, airplane sheet, bottle caps, zinc corners, iron attachments, dirt, corrosion, fiber, foam, or and/or fiberglass backing.

The extrudable fragmentizer aluminum scrap composition can be known under the ISRI code TWEAK. As generally understood, the fragmentizer aluminum scrap composition can be derived from either mechanical or hand separation, the TWEAK must be dry and not contain more than 4% maximum free zinc, 1% maximum free magnesium, and 1.5% maximum of analytical iron. Fragmentizer aluminum scrap cannot include more than a total 5% maximum of non-metallics, of which no more than 1% shall be rubber and plastics. The fragmentizer aluminum scrap composition is free of excessively oxidized material, air bag canisters, or any sealed or pressurized items.

Either the floated fragmentizer aluminum scrap composition or fragmentizer aluminum scrap composition are typically obtained from aluminum scrap characterized as ISRI code ZORBA scrap. ZORBA scrap is one of the most commonly sourced grades of aluminum scrap and is generally the collective term for shredded/pre-treated Aluminum scrap metal.

ZORBA scrap is a mixed non-ferrous material generated by eddy-current separators in the recycling of automobiles, end-of-life vehicles (ELVs), waste electrical, and electronic equipment (WEEE), white goods (large household electrical items) and other aluminum scraps.

ZORBA scrap primarily includes aluminum (e.g., about 70-90%) and other non-ferrous metals like copper, brass and zinc, as well as magnesium generated by eddy-current separators. Additionally, ZORBA scrap can contain non-metallic contaminants such as rubber and foil 0.01%.

The fragmentizer aluminum scrap composition is either hand separated or mechanically separated from ZORBA scrap. The floated fragmentizer aluminum scrap composition undergoes an additional step relative to the fragmentizer aluminum scrap composition.

The floated fragmentizer aluminum scrap composition can be generated by a sink-float (heavy-media) separation technique. Sink-float (heavy-media, density) separation is a wet process that utilizes the known specific gravities of water-based slurries to separate non-ferrous metals and plastics with varying densities. As an example of a process, first, fine particles are screened out of the mixed metallic stream. Conveyor belts carry the ZORBA scrap stream to a rotating drum where the first slurry, a 2.1-2.5 specific gravity bath, is used to separate out the magnesium and denser plastics from the other metals present. The control of the bath's specific gravity is attributed to the use of magnetite or ferrosilicon powder. The final bath (3.1-3.5 specific gravity) is used to float out the cast and wrought aluminum while the heavier metal components such as copper, zinc and lead sink to a different conveyor belt. The lighter aluminum scrap mix is classified by ISRI as TWITCH (floating fraction) and the heavier metals as ZEBRA (sinking fraction). The TWITCH can be classified as mixed or sorted. In general, mixed TWITCH can include more impurities than sorted TWITCH. Advantageously, the instantly disclosed methods can use mixed TWITCH as a feedstock, which may not be feasible using conventional extrusion techniques.

The floated fragmentizer aluminum scrap, fragmentizer aluminum scrap, or both can include one or more impurities. Examples of impurities that can be present include silicon, copper, iron, magnesium, manganese, zinc, or a mixture of at least two thereof. In applications where the floated fragmentizer aluminum scrap is used as an extrusion feedstock a certain amount of at least one of these impurities may be tolerated. That is an extruded product may include these impurities and still have adequate physical properties such as yield strength, ultimate tensile strength, elongation percentage or the like.

However, using conventional extrusion techniques, there is an upper limit on the concentration of these impurities that can be present in the feedstock and/extruded product before any one or more of the extruded product's physical properties becomes inadequate. To mitigate the potential drop in performance, it may be necessary to subject the floated fragmentizer aluminum scrap or fragmentizer aluminum scrap to additional processing steps to remove any one or more of these impurities. However, this adds time, complexity, and cost to the entire process. The impurities can even require diluting the impurities with virgin aluminum which can nullify much of the environmental and economic benefits of recycling scrap aluminum.

However, the inventors have surprisingly and unexpectedly found that these impurities can be tolerated if the extrusion feedstock is subjected to a Shear Assisted Processing and Extrusion (ShAPE) extrusion process. That is, any one or more of the aforementioned impurities can be present in the extrusion feedstock at a concentration that would otherwise be considered to be too high to be tolerated in a conventionally extruded product. Allowing for relatively high impurities levels, while forming adequate extrusion products can allow for a wider variety of floated fragmentizer aluminum scrap materials or fragmentizer aluminum scrap materials to be used and save on costs and time that would otherwise be dedicated to removing the one or more impurities.

As an example of the concentrations of impurities that the extrudable floated fragmentizer aluminum scrap, extrudable fragmentizer aluminum scrap composition, or an extrudable mixture thereof can accommodate, silicon can be in a range of from about 2 wt % to about 15 wt % of the extrudable floated fragmentizer aluminum scrap, extrudable fragmentizer aluminum scrap composition, or an extrudable mixture thereof, about 4 wt % to about 15 wt %, less than, equal to, or greater than about 2 wt %, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, 5, 5.1, 5.2, 5.3, 5.4, 5.5, 5.6, 5.7, 5.8, 5.9, 6, 6.1, 6.2, 6.3, 6.4, 6.5, 6.6, 6.7, 6.8, 6.9, 7, 7.1, 7.2, 7.3, 7.4, 7.5, 7.6, 7.7, 7.8, 7.9, 8, 8.1, 8.2, 8.3, 8.4, 8.5, 8.6, 8.7, 8.8, 8.9, 9, 9.1, 9.2, 9.3, 9.4, 9.5, 9.6, 9.7, 9.8, 9.9, 10, 10.1, 10.2, 10.3, 10.4, 10.5, 10.6, 10.7, 10.8, 10.9, 11, 11.1, 11.2, 11.3, 11.4, 11.5, 11.6, 11.7, 11.8, 11.9, 12, 12.1, 12.2, 12.3, 12.4, 12.5, 12.6, 12.7, 12.8, 12.9, 13, 13.1, 13.2, 13.3, 13.4, 13.5, 13.6, 13.7, 13.8, 13.9, 14, 14.1, 14.2, 14.3, 14.4, 14.5, 14.6, 14.7, 14.8, 14.9, or about 15 wt %.

Copper can be in a range of from about 0.3 wt % to about 3 wt % of the extrudable floated fragmentizer aluminum scrap, extrudable fragmentizer aluminum scrap composition, or an extrudable mixture thereof, about 0.6 wt % to about 3 wt %, less than, equal to, or greater than about 0.3 wt %, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, or about 3 wt %.

Iron can be in a range of from about 0.2 wt % to about 2 wt % of the extrudable floated fragmentizer aluminum scrap, extrudable fragmentizer aluminum scrap composition, or an extrudable mixture thereof, about 0.3 wt % to about 2 wt %, less than, equal to, or greater than about 0.2 wt %, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, or about 2 wt %.

Magnesium can be in a range of from about 0.3 wt % to about 3 wt % of the extrudable floated fragmentizer aluminum scrap, extrudable fragmentizer aluminum scrap composition, or an extrudable mixture thereof, about 0.7 wt % to about 3 wt %, less than, equal to, or greater than about 0.3 wt %, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, or about 3 wt %.

Manganese can be in a range of from about 0.1 wt % to about 2 wt % of the extrudable floated fragmentizer aluminum scrap, extrudable fragmentizer aluminum scrap composition, or an extrudable mixture thereof, about 0.2 wt % to about 2 wt %, less than, equal to, or greater than about 0.1 wt %, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, or about 2 wt %.

Zinc can be in a range of from about 0.1 wt % to about 1 wt % of the extrudable floated fragmentizer aluminum scrap composition, extrudable fragmentizer aluminum scrap composition, or an extrudable mixture thereof, about 0.4 wt % to about 2 wt %, less than, equal to, or greater than about 0.5 wt %, 0.6, 0.7, 0.8, 0.9, 1, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, or about 2 wt %.

The one or more impurities can be present in the extrudable floated fragmentizer aluminum scrap composition, extrudable fragmentizer aluminum scrap composition, or an extrudable mixture thereof. That is the one or more impurities are included in the floated fragmentizer aluminum scrap as is. Alternatively, at least one of the impurities can be affirmatively spiked in the extrudable floated fragmentizer aluminum scrap composition, extrudable fragmentizer aluminum scrap composition, or an extrudable mixture thereof to achieve the concentrations described herein. Spiking the extrudable floated fragmentizer aluminum scrap composition, extrudable fragmentizer aluminum scrap composition, or an extrudable mixture thereof can be desirable in instances where the one or more impurities at a certain concentration impart desirable physical properties to the extruded product. In an example, the entirety of the concentration of the one or more impurities comes from passive impurities or spiked impurities, but the concentrations can also be a combination of the passive impurities and the spiked impurities.

The extrudable secondary aluminum scrap composition can be a manufacturing scrap, a post-consumer aluminum, or a mixture thereof. Examples of suitable secondary aluminum scrap compositions include a 5xxx series aluminum alloy, a 6xxx series aluminum alloy, a 7xxx series aluminum alloy, or a mixture of at least two thereof. Non-limiting examples of suitable 6xxx series aluminum alloys include AA6063, AA 6061, or AA 6082.

The extrudable floated fragmentizer aluminum scrap composition, extrudable fragmentizer aluminum scrap composition, extrudable secondary aluminum scrap composition, or an extrudable mixture thereof includes high levels of aluminum as a major component. For example, aluminum is at least 80 wt % of the extrudable floated fragmentizer aluminum scrap composition, extrudable fragmentizer aluminum scrap composition, extrudable secondary aluminum scrap composition, or an extrudable mixture thereof, at least 82 wt %, at least 85 wt %, at least 90 wt %, at least 95 wt %, in a range of from about 82 wt % to about 96 wt % or in a range of from about 85 wt % to about 91 wt % of the extrudable floated fragmentizer aluminum scrap composition, extrudable fragmentizer aluminum scrap composition, extrudable secondary aluminum scrap composition, or an extrudable mixture thereof.

The extrudable floated fragmentizer aluminum scrap composition, extrudable fragmentizer aluminum scrap composition, extrudable secondary aluminum scrap composition or an extrudable mixture thereof is considered to be a post-consumer composition. As generally understood, a post-consumer composition is material generated by households or by commercial, industrial and institutional facilities in their role as end-users of the product which can no longer be used for its intended purpose. This includes returns of material from the distribution chain. Examples of post-consumer scraps include a remelt scrap ingot (RSI), used beverage cans (UBC), or the like. By contrast a pre-consumer composition refers to a material diverted from a waste stream during a manufacturing process.

The extrusion feedstock described herein can include one or more materials in addition to the floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or a mixture thereof, fragmentizer aluminum scrap composition, extrudable secondary aluminum scrap composition, or a mixture thereof. For example, the extrusion feedstock can include a pre-consumer scrap composition; a post-consumer scrap composition, differing in chemical composition to the extrudable floated fragmentizer aluminum scrap composition, extrudable fragmentizer aluminum scrap composition, extrudable secondary aluminum scrap composition, or an extrudable mixture thereof; a primary aluminum; or a mixture of at least two thereof.

Primary aluminum is labeled as “primary” because it is made from new aluminum. Aluminum is derived from bauxite, a common ore found in topsoil in tropical and subtropical regions. Bauxite ore is chemically treated in a method called the Bayer process, which produces alumina, an aluminum oxide compound. The alumina is then smelted into new, pure aluminum ingots in a method called Hall-Héroult process. By contrast secondary aluminum gets its name from its source. It is referred to as “secondary” because it is made from recycled aluminum scrap. This scrap can come from all sorts of aluminum products and profiles, such as aluminum turnings, aluminum sheets, aluminum shreds, aluminum radiators, cast aluminum, extrusions, painted sidings, aluminum dross, and more. Generally, secondary aluminum has a higher concentration of alloying elements, such as iron, magnesium, and silicon (which can be added in the recycling process).

The pre-consumer scrap composition is a metallic scrap material (e.g., comprises greater than 50 wt % metal). While many different types of metals can be used, a particular example is of the pre-consumer scrap composition is a pre-consumer aluminum scrap material.

In examples where the extrusion feedstock includes a mixture of the extrudable floated fragmentizer aluminum scrap composition, extrudable fragmentizer aluminum scrap composition, extrudable secondary aluminum scrap composition, or an extrudable mixture thereof, the post-consumer scrap, and the pre-consumer scrap composition, each of the components independently ranges from about 1 wt % to about 99 wt % of the extrusion feedstock, about 5 wt % to about 95 wt %, about 20 wt % to about 80 wt % of the extrusion feedstock, about 25 wt % to about 75 wt %, less than, equal to, or greater than about 1 wt %, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, or about 99 wt % of the extrusion feedstock.

In examples where the extrusion feedstock includes a mixture of the extrudable floated fragmentizer aluminum scrap composition, extrudable fragmentizer aluminum scrap composition, extrudable secondary aluminum scrap composition, or an extrudable mixture thereof and the pre-consumer scrap composition, each of the components independently ranges from about 1 wt % to about 99 wt % of the extrusion feedstock, about 5 wt % to about 95 wt %, about 20 wt % to about 80 wt % of the extrusion feedstock, about 25 wt % to about 75 wt %, less than, equal to, or greater than about 1 wt %, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, or about 99 wt % of the extrusion feedstock.

In examples where the extrusion feedstock includes the post-consumer scrap composition and the extrudable floated fragmentizer aluminum scrap composition, extrudable fragmentizer aluminum scrap composition, extrudable secondary aluminum scrap composition, or an extrudable mixture thereof, each of the components independently ranges from about 1 wt % to about 99 wt % of the extrusion feedstock, about 5 wt % to about 95 wt %, about 20 wt % to about 80 wt % of the extrusion feedstock, about 25 wt % to about 75 wt %, less than, equal to, or greater than about 1 wt %, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, or about 99 wt % of the extrusion feedstock.

The alloying element composition can include one or more of silicon, copper, iron, magnesium, chromium, manganese, zinc, oxygen, a rare earth element, or a mixture of at least two thereof. The alloying element composition can account for about 0.01 wt % to about 60 wt % of the extrusion feedstock, about 7 wt % to about 30 wt %, less than, equal to, or greater than about 0.01 wt %, 0.05, 0.1, 0.2, 0.3, 0.4, 0.5, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, or about 60 wt %.

Silicon can be present in a range of from about 0.01 to about 15 wt % of the alloying element composition, about 0.5 to about 12 wt %, less than equal to, or greater than about 0.01 wt % of the alloying element composition, 0.05, 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5, 6, 6.5, 7, 7.5, 8, 8.5, 9, 9.5, 10, 10.5, 11, 11.5, 12, 12.5, 13, 13.5, 14, 14.5, or about 15 wt % of the alloying element composition. Copper can be present in a range of from about 0.01 to about 7 wt % of the alloying element composition, about 0.5 to about 5 wt %, less than equal to, or greater than about 0.01 wt % of the alloying element composition, 0.05, 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, or about 5 wt % of the alloying element composition. Iron can be present in a range of from about 0.01 to about 6 wt % of the alloying element composition, about 0.5 to about 4 wt %, less than equal to, or greater than about 0.01 wt % of the alloying element composition, 0.05, 1, 1.5, 2, 2.5, 3, 3.5, or about 4 wt % of the alloying element composition. Magnesium can be present in a range of from about 0.01 to about 10 wt % of the alloying element composition, about 0.5 to about 8 wt %, less than equal to, or greater than about 0.01 wt % of the alloying element composition, 0.05, 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5, 6, 6.5, 7, 7.5, 8, 8.5, 9, 9.5, or about 10 wt % of the alloying element composition. Chromium can be present in a range of from about 0.01 to about 5 wt % of the alloying element composition, about 0.5 to about 3 wt %, less than equal to, or greater than about 0.01 wt % of the alloying element composition, 0.05, 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, or about 5 wt % of the alloying element composition. Manganese can be present in a range of from about 0.01 to about 5 wt % of the alloying element composition, about 0.5 to about 3 wt %, less than equal to, or greater than about 0.01 wt % of the alloying element composition, 0.05, 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, or about 5 wt % of the alloying element composition. Zinc can be present in a range of from about 0.01 to about 8 wt % of the alloying element composition, about 0.5 to about 5 wt %, less than equal to, or greater than about 0.01 wt % of the alloying element composition, 0.05, 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5, 6, 6.5, 7, 7.5, or about 8 wt % of the alloying element composition. Oxygen can be present in a range of from about 0.01 to about 15 wt % of the alloying element composition, about 0.5 to about 12 wt %, less than equal to, or greater than about 0.01 wt % of the alloying element composition, 0.05, 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5, 6, 6.5, 7, 7.5, 8, 8.5, 9, 9.5, 10, 10.5, 11, 11.5, 12, 12.5, 13, 13.5, 14, 14.5, or about 15 wt % of the alloying element composition. The rare earth element can be present in a range of from about 0.01 to about 15 wt % of the alloying element composition, about 0.5 to about 12 wt %, less than equal to, or greater than about 0.01 wt % of the alloying element composition, 0.05, 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5, 6, 6.5, 7, 7.5, 8, 8.5, 9, 9.5, 10, 10.5, 11, 11.5, 12, 12.5, 13, 13.5, 14, 14.5, or about 15 wt % of the alloying element composition.

The exact composition of the alloying element composition and concentration thereof can be selected depending on the desired properties of the extruded product. For example, the alloying elements can be added in stoichiometric amounts to achieve a specific alloy designation according to the Aluminum Association (AA) standards. As another example, the alloying elements include silicon (Si) and magnesium (Mg) to form Mg₂Si precipitates that enhance the strength of the high-performance alloy. As another example, the alloying elements include copper (Cu) to promote precipitation hardening and increase the yield strength of the high-performance alloy. As another example, the alloying elements include zinc (Zn) and magnesium (Mg) in proportions that facilitate the formation of Mg(Zn,Cu)₂ phases within the high-performance alloy. As another example, the alloying elements include a combination of manganese (Mn) and chromium (Cr) to improve the alloy's resistance to corrosion.

Contrary to conventional practice, the feedstock need not be homogenized prior to extrusion. However at least the aluminum scrap composition and alloying element composition can be homogenized prior to extrusion. In general, a homogenized aluminum feedstock refers to a mixture of aluminum and possibly other materials that has been processed after solidification to achieve a uniform distribution of its constituent elements and/or phases throughout the entire volume of the material. The purpose of homogenization is to eliminate or reduce segregation and to balance the distribution of alloying elements and impurities, which can occur during the casting process. In contrast, a non-homogenized feedstock, such as the one described herein, has not undergone this process. As a result, the non-homogenized feedstock may exhibit variations in composition and microstructure. However, as will be further described herein, the subsequent extrusion process, particularly when using a shear assisted extrusion device, may help to refine the microstructure and improve the properties of the final extruded product.

While the extrusion feedstock can take many different forms, a particular form of the extrusion feedstock is a billet. A feedstock billet is a solid length of material that has been either cast, extruded, or otherwise formed into a cylindrical or rectangular shape and is intended to be further processed, such as through forging or extrusion, to create a finished product. In the context of aluminum and its alloys, a billet can serve as a semi-finished product that is ready to be shaped into a final form.

The billet can have a substantially smooth surface finish, which can be helpful for the integrity of the final product, especially if the billet is to be further processed by extrusion. In an example, the billet can undergo various heat treatments to improve its mechanical properties or to prepare them for further processing. In general, billets can be processed into a wide range of products, including rods, bars, tubes, and profiles, making them a versatile starting material in the metal manufacturing industry.

The extrusion feedstock can simply be a powdered or solid (e.g., scrapped) mixture of the alloying element composition and at least one of the floated fragmentizer aluminum scrap, fragmentizer aluminum scrap, and secondary aluminum scrap that is placed in the extrusion device and fed therethrough. The feedstock does not have to be homogenized prior to extrusion, but it can be homogenized if desired. In some examples, the feedstock is compacted prior to extrusion.

Alternatively, the extrusion feedstock can be formed by melting feedstock material or combination of materials. This can involve heating the materials in a furnace or another suitable melting apparatus until they reach a molten state. If the extrusion feedstock includes additional components beyond the alloying element composition, floated fragmentizer aluminum scrap, fragmentizer aluminum scrap, extrudable secondary aluminum scrap, or mixture thereof, such as the pre-consumer scrap, post-consumer scrap, primary aluminum, or a mixture of at least two thereof, these materials are also melted and combined with the floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or a mixture thereof, fragmentizer aluminum scrap composition, or a mixture thereof. The combination can occur before or after the materials are introduced into the mold. The mold is designed to shape the molten material into a billet or another desired form as it solidifies.

The molten compositions can be mixed to achieve a more uniform distribution of the various components. In particular examples where the feedstock includes both floated fragmentizer aluminum scrap and fragmentizer aluminum scrap, those scraps can be mixed in any desired proportions. This can be done before solidification, ensuring that the different types of scrap and primary aluminum are well-integrated. After the molten aluminum composition (and any additional materials) is disposed into the mold, it is allowed to solidify. The solidification process may be controlled to affect the microstructure and properties in the resulting feedstock. For example, the temperature can be varied throughout the solidification process such as to increase or decrease the rate of solidification.

Once solidified, the material may be in the form of a billet or other structure, which can be further processed. The billet may undergo one or more additional treatments such as surface finishing or heat treatments to prepare it for extrusion. As stated previously, the extrusion feedstock may or may not be homogenized prior to extrusion. This means that the material need not undergo a process to make the composition and microstructure uniform throughout the feedstock. The lack of homogenization may be intentional to take advantage of certain properties that arise from the non-uniform distribution of elements.

Following solidification, the extrusion feedstock is ready to be used in an extrusion process, specifically through a Shear Assisted Processing and Extrusion (ShAPE) device as described further herein. As shown in FIGS. 1 and 2, examples of the ShAPE device and arrangement are provided. In an arrangement such as the one shown in FIG. 1, rotating die 10 is thrust into a material 20 under specific conditions whereby the rotating and shear forces of the die face 12 and the die shank 16 combine to heat and/or plasticize the material 20 at the interface of the die face 12 and the material 20 and cause the plasticized material to flow in a desired direction in either a direct or indirect manner. (In other embodiments the material 20 may spin and the die 10 may be pushed axially into the material 20 so as to provide this combination of forces at the material face.) In either instance, the combination of the axial and the rotating forces plasticize the material 20 at the interface with the die face 12. Flow of the plasticized material can then be directed to another location wherein a die bearing surface 24 of a preselected length facilitates the recombination of the plasticized material into an arrangement wherein a new and more refined grain size and texture control at the microscopic level can take place. This then translates to an extruded product 22 with desired characteristics. This process enables better strength, ductility, and corrosion resistance at the macroscopic level together with increased and better performance. This process can help reduce or eliminate the need for additional heating, and the process can utilize a variety of forms of material including billet, powder or flake without the need for extensive preparatory processes such as “steel canning”, billet pre-heating, de-gassing, or de-canning. Other process steps can be utilized as well. This arrangement also provides for a methodology for performing other steps such as cladding, enhanced control for through wall thickness and other characteristics, joining of dissimilar materials and alloys, and beneficial feedstock materials for subsequent rolling operations.

This arrangement is distinct from and provides a variety of advantages over the prior art methods for extrusion. First, during the extrusion process the force rises to a peak in the beginning and then falls off once the extrusion starts. This is called breakthrough.

In ShAPE the breakthrough force can be mitigated or eliminated by a combination of 1) the die features and rotation thereof funnel material into the throat, 2) heat generation at the die-feedstock interface warms the die throat allowing for the extrudate to flow through without substantial cooling, 3) the active and independently controllable rotation and thrust allow a gradual increase to the extrusion speed at the beginning of the extrusion. These effects, mitigating or eliminating the breakthrough force, can allow for a similar machine to extrude larger feedstocks and extrudate products, and can lessen peak stresses in the die which can prolong die life.

The ShAPE process is significantly different than Friction Stir Back Extrusion (FSBE). In FSBE, a spinning mandrel, sometimes called a tool, is rammed into a contained billet, much like a drilling operation. Scrolled grooves force material outward and material back extrudes around and onto the mandrel to form a tube, not having been forced through a die. As a result, only very small extrusion ratios are possible in FSBE, the tube is not fully processed through the wall thickness, the extrudate is not able to push off of the mandrel, and the tube length is limited to the extended length of the mandrel. In contrast, ShAPE utilizes spiral grooves (or other features) on a die face to feed material inward through a die and (optionally for hollow-centered profiles) around a mandrel that is traveling in the same direction as the extrudate. As such, a much larger outer diameter and extrusion ratio are possible, the material is uniformly processed through the wall thickness, the extrudate is free to push off the mandrel as in conventional extrusion, and the extrudate length is only limited only by the starting volume of the billet. ShAPE can be scalable to the manufacturing level, while the limitations of FSBE have kept the technology as a non-scalable academic interest since FBSE was first reported.

An example of an arrangement using a ShAPE device with a mandrel 18 is shown in FIG. 2. This device and associated processes have the potential to be a low-cost, manufacturing technique to fabricate variety of materials. As will be described below in more detail, in addition to modifying various parameters such as feed rate, heat, pressure and spin rates of the process, various mechanical elements of the tool assist to achieve various desired results. For example, varying scroll patterns 14 on the face of extrusion dies 12 can be used to affect or control a variety of features of the resulting materials. This can include control of grain size and crystallographic texture along the length of the extrusion and through-wall thickness of extruded tubing and other features. Alteration of parameters can be used to advantageously alter bulk material properties such as ductility and strength and allow tailoring for specific engineering applications including altering the resistance to crush, pressure or bending. Scroll patterns have also been found to affect process forces and grain size and texture through the thickness of the extrusion.

The ShAPE process has been utilized to form various structures from a variety of materials. In the previously described and related applications various methods and techniques are described wherein the ShAPE technique and device can provide a number of advantages including the ability to control microstructure such as crystallographic texture through the cross sectional thickness, while also providing the ability to perform various other tasks. In this description we provide information regarding the use of the ShAPE technique to form materials with non-circular hollow profiles as well as methods for creating high entropy alloys that are useful in a variety of applications. These two exemplary applications will be discussed in more detail in the following.

FIG. 3 shows a schematic of the ShAPE process which utilizes rotating die 25 apply load or pressure to billet area 26 (where a billet is loaded), disposed within container 27. Ram 28 pushes billet 26 through the device.

Generally, in shear-assisted extrusion techniques as shown and described herein (such as in relation to the apparatus of FIG. 1 and FIG. 2), both an axial force and a rotational force are applied to a material of interest causing the material to heat and plasticize. In extrusion applications, the plasticized material then flows over a die bearing surface dimensioned so as to allow recombination of the plasticized materials in an arrangement with superior grain size distribution and alignment than what is possible in traditional extrusion processing. As described in the prior related applications this process can provide a number of advantages and features that conventional prior art extrusion processing is simply unable to achieve. ShAPE processing also supports extrusion a variety of different shapes and internal profiles, including circular, solid, hollow (e.g., using a mandrel), and non-circular or asymmetric extrudates (e.g., using a porthole die configuration).

The extruded product using ShAPE, is a new alloy relative to those in the feedstock. The type of alloy formed, as well as the formed alloy's mechanical properties, are customizable depending on the alloying element(s) that are added. For example, if the feedstock includes a AA6xxx series alloy, the extruded product can be an AA7xxx series alloy. In addition to the chemical composition being different, the microstructure of the extruded product is different from that of the extrusion feedstock. The term “microstructure” refers to the structure of the extruded product as revealed by a microscope. The microstructure generally can include the arrangement of grains, phases, inclusions, and any other features that are typically on the scale of micrometers (one millionth of a meter).

The microstructure is a factor in determining the properties of a metal, extruded product as its mechanical strength, ductility, toughness, hardness, corrosion resistance, and fatigue life. ShAPE extrusion manipulates the microstructure of the extruded product, relative to the extrusion feedstock, such that an average grain size of the extrusion product that is smaller in at least one dimension relative to the corresponding non-extruded product (e.g., extrusion feedstock). As a particular example, in the extruded product the average grain length of the product's microstructure is smaller than an average grain length of the extrusion feedstock.

The refined microstructure can overcome drawbacks associated with the presence of the aforementioned impurities present in floated fragmentizer aluminum scrap and fragmentizer aluminum scrap. For example, higher silicon concentrations cause a decrease in ductility in an aluminum product extruded using a non-shear-assisted extrusion technique. However, when a shear-assisted extrusion approach is used, a refined microstructure provides enhanced ductility by reducing the size of any grains including silicon and thus reducing silicon's negative effects. In general, ShAPE extrusion can help to reduce the assumed negative impacts of the aforementioned impurities by reducing the size of the grains that include the impurities and therefore minimizing the impact of the impurities.

ShAPE imparts many favorable physical properties into the extruded product of the floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or mixture thereof. For example, a yield strength of the extruded product can range from about 200 MPa to about 350 MPa, about 263 MPa to about 294 MPa, less than, equal to, or greater than about 200 MPa, 205, 210, 215, 220, 225, 230, 235, 240, 245, 250, 255, 260, 265, 270, 275, 280, 285, 290, 295, 300, 305, 310, 315, 320, 325, 330, 335, 340, 345, or about 350 MPa. As understood, yield strength refers to the stress at which a material begins to deform plastically. Once the yield point is passed, some degree of permanent deformation will occur, and the material will not return to its original shape when the applied stress is removed. The yield strength is an intrinsic property of the material and is determined by its microstructure, which can be influenced by the ShAPE extrusion, as well as any subsequent heat treatments or work hardening.

An ultimate tensile strength of the extruded product including the floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or mixture thereof can range from about 300 MPa to about 400 MPa, about 326 MPa to about 366 MPa, less than, equal to, or greater than about 300 MPa, 305, 310, 315, 320, 325, 330, 335, 340, 345, 350, 355, 360, 365, 370, 375, 380, 385, 390, 395, or about 400 MPa. As understood, ultimate tensile strength, also known as tensile strength, is the maximum stress that a material can withstand while being stretched or pulled before necking, which is when the specimen's cross-section starts to significantly contract. Ultimate tensile strength is an important measure of the mechanical properties of materials, including extruded products. For the extruded product, the ultimate tensile strength represents the peak stress that the material can sustain during a tensile test before it breaks or fails. This property is helpful for understanding the material's ability to resist breaking under tension and is a helpful factor in the design and application of the extruded material.

Generally, the ultimate tensile strength is determined by performing a tensile test where a sample of the extruded product is subjected to a controlled and steadily increasing elongation and corresponding tensile force until failure. The maximum force that the material sustains divided by the original cross-sectional area of the sample gives the ultimate tensile strength.

An elongation percentage of the extruded product including the floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or mixture thereof can be in a range of from about 5% to about 20%, about 8% to about 12%, less than, equal to, or greater than about 5%, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, or about 20%. As understood, elongation percentage is a measure of ductility, which is the ability of the extruded product to deform plastically before fracturing. It can be expressed as a percentage and is calculated from the increase in length of a tensile test extruded product at the moment of fracture compared to its original length. The elongation percentage is a helpful indicator of how much the extruded product can stretch or elongate, which can be a characteristic property in applications where the material is expected to undergo a degree of deformation without breaking. High elongation percentages indicate a more ductile material, while low elongation percentages indicate a more brittle material.

The extruded products can be formed into many different parts or portions of parts. The extruded products described herein can be used as other extruded product of aluminum can be used. Like pure aluminum extrusion products, the extruded products described herein are desirable because they are lightweight, strong, corrosion-resistant, and easily workable.

While the extruded products described herein can be used for many different applications, they can be particularly suitable as a construction part. For example, the extruded product can be a window frame and/or door frame. Additionally, the extruded product can be at least a part of a curtain wall system, which is a non-structural outer covering of a building. Additionally, the extruded product can be at least part of a roofing system and/or awning (e.g., used as a structural support, edge trim, and/or gutter system). Additionally, the extruded product can be used as a siding and/or cladding. Additionally, the extruded product can be a railing and/or balustrade. Additionally, the extruded product can be a structural beam and/or support. Additionally, the extruded product can be a solar panel frame. Additionally, the extruded product can be a HVAC component (e.g., duct or heat exchanger frame). Additionally, the extruded product can be an electrical conduit and/or tray. Additionally, the extruded product can be a flooring and/or decking. Additionally, the extruded product can be a ceiling grid. Additionally, the extruded product can be an expansion joint.

There are additional forms that the extruded product can take beyond those described above. In general, the extruded product can be any product that uses an extruded aluminum product. For example, the extruded product can be an automotive part such as a roof rack, trim part, heat sink, bumper beam, and/or chassis component. The extruded product can be an electrical component such as an electrical enclosure, wire conduit, and/or busbar. The extruded product can be a consumer product such as a furniture frame, bicycle frame or component, sporting good. The extruded product can be an aerospace component such as a seat track and/or airframe structure. The extruded product can be a marine component such as a mast and boom section or a component of a dock and/or deck.

The extruded products described herein are additionally beneficial to use because they have the potential to be made in an environmentally friendly way and generate cost savings. In general, recycled aluminum products generate about 95% less carbon dioxide, require about 95% less energy, produce about 90% less solid waste, and cost about 59% less, during production than primary aluminum. These savings can be even greater in the extruded product described herein because the impurities do not need to be removed to the same degree as a product that is not extruded using ShAPE.

Examples

Various aspects of the present disclosure can be better understood by reference to the following Examples which are offered by way of illustration. The present invention is not limited to the Examples given herein.

The physical properties of various extruded products were assessed. Specifically scrap aluminum AA6063 alone was recycled through ShAPE and a mixture of aluminum AA6063 and at least one alloying element composition was extruded though ShAPE.

To prepare the recycled product, aluminum AA6063 was cold compacted in a billet container. Then, the container was loaded in the ShAPE device. Friction extrusion was applied to consolidate and extrude solid Al alloy wire in a single-step. Extrusion occurred at 100-300 rpm at 2-6 mm/min. The extruded product is a wire.

To prepare the upcycled product, Alloying element powder, or flakes, were added and mixed with AA6063 chips to make 5 gram mixture with a same chemical composition of AA7075. Many of these mixtures were cold compacted in a billet container. Then, the container was loaded in the ShAPE device. Friction extrusion was applied to homogenize and consolidate the precursor, and to extrude solid AA7075 wire in a single-step. Extrusion occurred at 100-300 rpm at 1.5-6 mm/min. The extruded product is a wire.

FIG. 4 is a XRD graph showing the chemical constituted of the recycled product and upcycled product. As shown, XRD data verifies the existence of newly-formed n/Mg(CuZn)₂ phases in the upcycle specimen. Specifically, in the current study, Mg(CuZn)₂ phase is identified as MgCu_0.54Zn_1.46.

FIG. 5 is an image showing the microstructure in the upcycled product. As shown, The additional particles of Zn, Mg, Cu are refined, uniformly dispersed, and dissolved in the matrix, promoted and enhanced via shear deformation at solid phase.

FIG. 6A is a graph showing the standard hardness values of the recycled product and FIG. 6B is a graph showing the standard hardness of the upcycled product.

FIG. 7 is a graph showing the respective Vickers hardness values of the upcycled and recycled product relative to the center of the respective extruded wire. As shown, the hardness of the upcycled product was about three times more than the recycled product.

The recycled product was compared to a standard recycled aluminum AA6063 (e.g., an aluminum AA6063 not extruded with ShAPE). Additionally, the upcycled product was compared to a reference aluminum AA7075. Results are shown in FIGS. 8-13. As shown in FIGS. 8-13, the recycled product and the upcycled product that had each been formed with ShAPE outperformed or was substantially the same as their respective standards in hardness, stress, yield strength, tensile strength, and elongation before break.

Throughout this document, values expressed in a range format should be interpreted in a flexible manner to include not only the numerical values explicitly recited as the limits of the range, but also to include all the individual numerical values or sub-ranges encompassed within that range as if each numerical value and sub-range is explicitly recited. For example, a range of “about 0.1% to about 5%” or “about 0.1% to 5%” should be interpreted to include not just about 0.1% to about 5%, but also the individual values (e.g., 1%, 2%, 3%, and 4%) and the sub-ranges (e.g., 0.1% to 0.5%, 1.1% to 2.2%, 3.3% to 4.4%) within the indicated range. The statement “about X to Y” has the same meaning as “about X to about Y,” unless indicated otherwise. Likewise, the statement “about X, Y, or about Z” has the same meaning as “about X, about Y, or about Z,” unless indicated otherwise.

In this document, the terms “a,” “an,” or “the” are used to include one or more than one unless the context clearly dictates otherwise. The term “or” is used to refer to a nonexclusive “or” unless otherwise indicated. The statement “at least one of A and B” or “at least one of A or B” has the same meaning as “A, B, or A and B.” In addition, it is to be understood that the phraseology or terminology employed herein, and not otherwise defined, is for the purpose of description only and not of limitation. Any use of section headings is intended to aid reading of the document and is not to be interpreted as limiting; information that is relevant to a section heading may occur within or outside of that particular section.

All publications, patents, and patent documents referred to in this document are incorporated by reference herein in their entirety, as though individually incorporated by reference. In the event of inconsistent usages between this document and those documents so incorporated by reference, the usage in the incorporated reference should be considered supplementary to that of this document; for irreconcilable inconsistencies, the usage in this document controls.

In the methods described herein, the acts can be carried out in any order without departing from the principles of the invention, except when a temporal or operational sequence is explicitly recited. Furthermore, specified acts can be carried out concurrently unless explicit claim language recites that they be carried out separately. For example, a claimed act of doing X and a claimed act of doing Y can be conducted simultaneously within a single operation, and the resulting process will fall within the literal scope of the claimed process.

The term “about” as used herein can allow for a degree of variability in a value or range, for example, within 10%, within 5%, or within 1% of a stated value or of a stated limit of a range, and includes the exact stated value or range.

The term “substantially” as used herein refers to a majority of, or mostly, as in at least about 50%, 60%, 70%, 80%, 90%, 95%, 96%, 97%, 98%, 99%, 99.5%, 99.9%, 99.99%, or at least about 99.999% or more, or 100%.

The term “substantially free of” as used herein can mean having none or having a trivial amount of, such that the amount of material present does not affect the material properties of the composition including the material, such that about 0 wt % to about 5 wt % of the composition is the material, or about 0 wt % to about 1 wt %, or about 5 wt % or less, or less than or equal to about 4.5 wt %, 4, 3.5, 3, 2.5, 2, 1.5, 1, 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3, 0.2, 0.1, 0.01, or about 0.001 wt % or less, or about 0 wt %.

Exemplary Aspects

The following exemplary embodiments are provided, the numbering of which is not to be construed as designating levels of importance:

Aspect 1 provides an extrusion feedstock comprising:

• • at least 1 wt % of aluminum scrap composition comprising:
    • an extrudable floated fragmentizer aluminum scrap composition;
    • an extrudable fragmentizer aluminum scrap composition;
    • an extrudable secondary aluminum scrap composition; or
    • a mixture of at least two thereof; and
  • at least 0.01 wt % of an alloying element composition at least partially intermixed relative to the aluminum scrap composition, the alloying element composition comprising:
    • silicon in a range of from about 0.01 to about 15 wt % of the alloying element composition;
    • copper in a range of from about 0.01 to about 7 wt % of the alloying element composition;
    • iron in a range of from about 0.01 to about 6 wt % of the alloying element composition
    • magnesium in a range of from about 0.01 to about 10 wt % of the alloying element composition;
    • chromium in a range of from about 0.01 to about 5 wt % of the alloying element composition;
    • manganese in a range of from about 0.01 to about 5 wt % of the alloying element composition;
    • zinc in a range of from about 0.01 to about 8 wt % of the alloying element composition;
    • oxygen in a range of from about 0.01 to about 15 wt % of the alloying element composition;
    • a rare earth element in a range of from about 0.01 to about 15 wt % of the alloying element composition; or
    • a mixture of at least two thereof.

Aspect 2 provides the extrusion feedstock of Aspect 1, wherein the floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or both comprise an impurity, the impurity comprising at least one of:

• • silicon in a range of from about 0.3 wt % to about 10 wt % of the extrudable floated fragmentizer aluminum scrap composition;
  • copper in a range of from about 1 wt % to about 3 wt % of the extrudable floated fragmentizer aluminum scrap composition;
  • iron in a range of from about 0.2 wt % to about 2 wt % of the extrudable floated fragmentizer aluminum scrap composition;
  • magnesium in a range of from about 0.3 wt % to about 3 wt % of the extrudable floated fragmentizer aluminum scrap composition;
  • manganese in a range of from about 0.1 wt % to about 2 wt % of the extrudable floated fragmentizer aluminum scrap composition;
  • zinc in a range of from about 0.1 wt % to about 1 wt % of the extrudable floated fragmentizer aluminum scrap composition; or
  • a mixture of at least two thereof.

Aspect 3 provides the extrusion feedstock of any of Aspects 1 or 2, wherein aluminum is at least 80 wt % of the aluminum scrap composition.

Aspect 4 provides the extrusion feedstock of any of Aspects 1-3, wherein aluminum is at least 82 wt % of the aluminum scrap composition.

Aspect 5 provides the extrusion feedstock of any of Aspects 1-4, wherein aluminum is in a range of from about 82 wt % to about 96 wt % of the aluminum scrap composition.

Aspect 6 provides the extrusion feedstock of any of Aspects 1-5, wherein aluminum is in a range of from about 85 wt % to about 91 wt % of the extrudable floated fragmentizer aluminum scrap composition.

Aspect 7 provides the extrusion feedstock of any of Aspects 2-6, wherein the impurity comprises at least one of:

• • silicon in a range of from about 2 wt % to about 10 wt % of the floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or both;
  • copper in a range of from about 1.6 wt % to about 3 wt % of the floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or both;
  • iron in a range of from about 0.3 wt % to about 2 wt % of the floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or both;
  • magnesium in a range of from about 0.7 wt % to about 3 wt % of the floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or both;
  • manganese in a range of from about 0.2 wt % to about 2 wt % of the floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or both;
  • zinc in a range of from about 0.4 wt % to about 2 wt % of the floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or both; or
  • a mixture of at least two thereof.

Aspect 8 provides the extrusion feedstock of any of Aspects 2-7, wherein the impurity comprises silicon in a range of from about 0.3 wt % to about 10 wt % of the floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or both.

Aspect 9 provides the extrusion feedstock of any of Aspects 2-8, wherein the impurity comprises copper in a range of from about 1 wt % to about 3 wt % of the floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or both.

Aspect 10 provides the extrusion feedstock of any of Aspects 2-9, wherein the impurity comprises iron in a range of from about 0.2 wt % to about 2 wt % of the floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or both.

Aspect 11 provides the extrusion feedstock of any of Aspects 2-10, wherein the impurity comprises magnesium in a range of from about 0.3 wt % to about 3 wt % of the floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or both.

Aspect 12 provides the extrusion feedstock of any of Aspects 2-11, wherein the impurity comprises manganese in a range of from about 0.2 wt % to about 2 wt % of the floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or both.

Aspect 13 provides the extrusion feedstock of any of Aspects 2-12, wherein the impurity comprises zinc in a range of from about 0.1 wt % to about 1 wt % of the floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or both.

Aspect 14 provides the extrusion feedstock of any of Aspects 2-13, wherein the impurity comprises:

• • silicon in a range of from about 2 wt % to about 10 wt % of floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or both;
  • copper in a range of from about 1 wt % to about 3 wt % of the floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or both;
  • iron in a range of from about 0.2 wt % to about 2 wt % of floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or both;
  • magnesium in a range of from about 0.3 wt % to about 3 wt % of the floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or both; and
  • manganese in a range of from about 0.2 wt % to about 2 wt % of floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or both.

Aspect 15 provides the extrusion feedstock of any of Aspects 1-14, wherein the extrudable secondary aluminum scrap composition comprises a 5xxx series aluminum alloy, a 6xxx series aluminum alloy, a 7xxx series aluminum alloy, or a mixture of at least two thereof.

Aspect 16 provides the extrusion feedstock of Aspect 15, wherein the extrudable secondary aluminum scrap composition comprises an AA6063 alloy.

Aspect 17 provides the extrusion feedstock of any of Aspects 1-16, wherein the alloying element composition is in a range of from about 5 to about 60 wt % of the feedstock.

Aspect 18 provides the extrusion feedstock of any of Aspects 1-17, further comprising at least one of:

• • a pre-consumer scrap composition;
  • a post-consumer scrap composition differing in chemical composition to the extrudable floated fragmentizer aluminum scrap composition;
  • a primary aluminum; or
  • a mixture of at least two thereof.

Aspect 19 provides the extrusion feedstock Aspect 18, wherein the pre-consumer scrap composition is a pre-consumer aluminum scrap material.

Aspect 20 provides the extrusion feedstock of any of Aspects 18 or 19, wherein the aluminum scrap composition, the alloying element composition, the post-consumer scrap, and the pre-consumer scrap composition independently range from about 1 wt % to about 99 wt % of the extrusion feedstock.

Aspect 21 provides the extrusion feedstock of any of Aspects 18-20, wherein the aluminum scrap composition, the alloying element composition, the post-consumer scrap, and the pre-consumer scrap composition independently range from about 5 wt % to about 95 wt % of the extrusion feedstock.

Aspect 22 provides the extrusion feedstock of any of Aspects 18-21, wherein the aluminum scrap composition, the alloying element composition, the post-consumer scrap, and the pre-consumer scrap composition independently range from about 20 wt % to about 80 wt % of the extrusion feedstock.

Aspect 23 provides the extrusion feedstock of any of Aspects 18-22, wherein the aluminum scrap composition, the alloying element composition, the post-consumer scrap, and the pre-consumer scrap composition independently range from about 25 wt % to about 75 wt % of the extrusion feedstock.

Aspect 24 provides the extrusion feedstock of any of Aspects 18-23, wherein the aluminum scrap composition, the alloying element composition, and the pre-consumer scrap composition independently range from about 1 wt % to about 99 wt % of the extrusion feedstock.

Aspect 25 provides the extrusion feedstock of any of Aspects 18-24, wherein the aluminum scrap composition, the alloying element composition, and the pre-consumer scrap composition independently range from about 5 wt % to about 95 wt % of the extrusion feedstock.

Aspect 26 provides the extrusion feedstock of any of Aspects 18-25, wherein aluminum scrap composition, the alloying element composition, and the pre-consumer scrap composition independently range from about 20 wt % to about 80 wt % of the extrusion feedstock.

Aspect 27 provides the extrusion feedstock of any of Aspects 18-26, wherein aluminum scrap composition, the alloying element composition, and the pre-consumer scrap composition independently range from about 25 wt % to about 75 wt % of the extrusion feedstock.

Aspect 28 provides the extrusion feedstock of any of Aspects 18-27, wherein the aluminum scrap composition, the alloying element composition, and the pre-consumer scrap composition each comprise about 50% of the extrusion feedstock.

Aspect 29 provides the extrusion feedstock of any of Aspects 18-28, wherein the post-consumer scrap composition, the alloying element composition, and the aluminum scrap composition, independently range from about 1 wt % to about 99 wt % of the extrusion feedstock.

Aspect 30 provides the extrusion feedstock of any of Aspects 18-29, wherein the post-consumer scrap composition, the alloying element composition, and the aluminum scrap composition independently range from about 5 wt % to about 95 wt % of the extrusion feedstock.

Aspect 31 provides the extrusion feedstock of any of Aspects 18-30, wherein the post-consumer scrap composition, the alloying element composition, and the aluminum scrap composition independently range from about 20 wt % to about 80 wt % of the extrusion feedstock.

Aspect 32 provides the extrusion feedstock of any of Aspects 18-31, wherein the post-consumer scrap composition, the alloying element composition, and the aluminum scrap composition independently range from about 25 wt % to about 75 wt % of the extrusion feedstock.

Aspect 33 provides the extrusion feedstock of any of Aspects 18-32, wherein the post-consumer scrap composition, the alloying element composition, and the aluminum scrap composition each comprise about 50 wt % of the extrusion feedstock.

Aspect 34 provides the extrusion feedstock of any of Aspects 1-33, wherein the feedstock is not homogenized.

Aspect 35 provides the extrusion feedstock of any of Aspects 1-34, wherein at least the extrudable floated fragmentizer aluminum scrap composition and the alloying element composition are homogenized.

Aspect 36 provides the extrusion feedstock of any of Aspects 1-35, wherein the feedstock is a billet.

Aspect 37 provides the extrusion feedstock of any of Aspects 1-36, wherein the extrusion feedstock is extrudable through a shear assisted extrusion device.

Aspect 38 provides the extrusion feedstock of Aspect 37, wherein the shear assisted extrusion device forms a high-performance alloy having a refined microstructure relative to a corresponding high-performance alloy that is not extruded by a shear assisted extrusion device.

Aspect 39 provides the extrusion feedstock of Aspect 38, wherein the refined microstructure comprises an average grain size that is smaller in at least one dimension relative to a corresponding non-extruded product.

Aspect 40 provides the extrusion feedstock of any of Aspects 38 or 39, wherein the refined microstructure comprises an average grain length that is smaller than an average grain length of a corresponding non-extruded product.

Aspect 41 provides the extrusion feedstock of any of Aspects 38-40, wherein the impurities present in the refined microstructure are broken down to smaller pieces relative to the impurities in a corresponding non-extruded product.

Aspect 42 provides the extrusion feedstock of any of Aspects 38-41, wherein an average grain length of the extruded product of the extrusion feedstock is less than about 10 μm.

Aspect 43 provides the extrusion feedstock of any of Aspects 37-42, wherein the shear assisted extrusion device disperses the alloying element composition to form a high-performance alloy.

Aspect 44 provides the extrusion feedstock of any of Aspects 37-43, wherein the shear assisted extrusion device produces an alloy having phases formed that are not present in the extrusion feedstock.

Aspect 45 provides the extrusion feedstock of any of Aspects 37-44, wherein a high-performance alloy produced by the shear assisted extrusion device exhibits increased mechanical properties compared to the aluminum scrap composition.

Aspect 46 provides the extrusion feedstock of any of Aspects 1-45, wherein the alloying elements include silicon (Si) and magnesium (Mg) to form Mg₂Si precipitates that enhance the strength of the high-performance alloy.

Aspect 47 provides the extrusion feedstock of any of Aspects 1-46, wherein the alloying elements include copper (Cu) to promote precipitation hardening and increase the yield strength of the high-performance alloy.

Aspect 48 provides the extrusion feedstock of any of Aspects 1-47, wherein the alloying elements include zinc (Zn) and magnesium (Mg) in proportions that facilitate the formation of Mg(Zn,Cu)₂ phases within the high-performance alloy.

Aspect 49 provides the extrusion feedstock of any of Aspects 1-48, wherein the alloying elements are added in stoichiometric amounts to achieve a specific alloy designation according to the Aluminum Association (AA) standards.

Aspect 50 provides the extrusion feedstock of any of Aspects 1-49, wherein the alloying elements include a combination of manganese (Mn) and chromium (Cr) to improve the alloy's resistance to corrosion.

Aspect 51 provides a method of forming a high-performance alloy, the method comprising:

• • using a shear assisted extrusion device, providing relative rotation between an extrusion die face and a feedstock;
  • applying a relative axial translating force between the extrusion die face and the feedstock sufficient to heat and plasticize, and mix the feedstock at an interface between the feedstock and the extrusion die face to form an alloy that is extruded through an aperture of the die;
  • wherein, the feedstock comprises:
    • at least 1 wt % of aluminum scrap composition comprising:
      • an extrudable floated fragmentizer aluminum scrap composition;
      • an extrudable fragmentizer aluminum scrap composition;
      • an extrudable secondary aluminum scrap composition; or
      • a mixture of at least two thereof; and
    • at least 0.01 wt % of an alloying element composition at least partially intermixed relative to the aluminum scrap composition, the alloying element composition comprising:
    • silicon in a range of from about 0.01 to about 15 wt % of the alloying element composition;
    • copper in a range of from about 0.01 to about 7 wt % of the alloying element composition;
    • iron in a range of from about 0.01 to about 6 wt % of the alloying element composition
    • magnesium in a range of from about 0.01 to about 10 wt % of the alloying element composition;
    • chromium in a range of from about 0.01 to about 5 wt % of the alloying element composition;
    • manganese in a range of from about 0.01 to about 5 wt % of the alloying element composition;
    • zinc in a range of from about 0.01 to about 8 wt % of the alloying element composition;
    • oxygen in a range of from about 0.01 to about 15 wt % of the alloying element composition;
    • a rare earth element in a range of from about 0.01 to about 15 wt % of the alloying element composition; ora mixture of at least two thereof.

Aspect 52 provides the method of Aspect 51, wherein the floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or both comprise an impurity, the impurity comprising at least one of:

• • silicon in a range of from about 0.3 wt % to about 10 wt % of the extrudable floated fragmentizer aluminum scrap composition;
  • copper in a range of from about 1 wt % to about 3 wt % of the extrudable floated fragmentizer aluminum scrap composition;
  • iron in a range of from about 0.2 wt % to about 2 wt % of the extrudable floated fragmentizer aluminum scrap composition;
  • magnesium in a range of from about 0.3 wt % to about 3 wt % of the extrudable floated fragmentizer aluminum scrap composition;
  • manganese in a range of from about 0.1 wt % to about 2 wt % of the extrudable floated fragmentizer aluminum scrap composition;
  • zinc in a range of from about 0.1 wt % to about 1 wt % of the extrudable floated fragmentizer aluminum scrap composition; or a mixture of at least two thereof.

Aspect 53 provides the method of any of Aspects 51 or 52, wherein aluminum is at least 80 wt % of the aluminum scrap composition.

Aspect 54 provides the method of any of Aspects 51-53, wherein aluminum is at least 82 wt % of the aluminum scrap composition.

Aspect 55 provides the method of any of Aspects 51-54, wherein aluminum is in a range of from about 82 wt % to about 96 wt % of the aluminum scrap composition.

Aspect 56 provides the method of any of Aspects 51-55, wherein aluminum is in a range of from about 85 wt % to about 91 wt % of the extrudable floated fragmentizer aluminum scrap composition.

Aspect 57 provides the method of any of Aspects 52-56, wherein the impurity comprises at least one of:

• • silicon in a range of from about 2 wt % to about 10 wt % of the floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or both;
  • copper in a range of from about 1.6 wt % to about 3 wt % of the floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or both;
  • iron in a range of from about 0.3 wt % to about 2 wt % of the floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or both;
  • magnesium in a range of from about 0.7 wt % to about 3 wt % of the floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or both;
  • manganese in a range of from about 0.2 wt % to about 2 wt % of the floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or both;
  • zinc in a range of from about 0.4 wt % to about 2 wt % of the floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or both; or
  • a mixture of at least two thereof.

Aspect 58 provides the method of any of Aspects 52-57, wherein the impurity comprises silicon in a range of from about 0.3 wt % to about 10 wt % of the floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or both.

Aspect 59 provides the method of any of Aspects 52-58, wherein the impurity comprises copper in a range of from about 1 wt % to about 3 wt % of the floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or both.

Aspect 60 provides the method of any of Aspects 52-59, wherein the impurity comprises iron in a range of from about 0.2 wt % to about 2 wt % of the floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or both.

Aspect 61 provides the method of any of Aspects 52-60, wherein the impurity comprises magnesium in a range of from about 0.3 wt % to about 3 wt % of the floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or both.

Aspect 62 provides the method of any of Aspects 52-61, wherein the impurity comprises manganese in a range of from about 0.2 wt % to about 2 wt % of the floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or both.

Aspect 63 provides the method of any of Aspects 52-62, wherein the impurity comprises zinc in a range of from about 0.1 wt % to about 1 wt % of the floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or both

Aspect 64 provides the method of any of Aspects 52-63, wherein the impurity comprises:

• • silicon in a range of from about 2 wt % to about 10 wt % of floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or both;
  • copper in a range of from about 1 wt % to about 3 wt % of the floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or both;
  • iron in a range of from about 0.2 wt % to about 2 wt % of floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or both;
  • magnesium in a range of from about 0.3 wt % to about 3 wt % of the floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or both; and
  • manganese in a range of from about 0.2 wt % to about 2 wt % of floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or both.

Aspect 65 provides the method of any of Aspects 51-64, wherein the extrudable secondary aluminum scrap composition comprises a 5xxx series aluminum alloy, a 6xxx series aluminum alloy, a 7xxx series aluminum alloy, or a mixture of at least two thereof.

Aspect 66 provides the method of Aspect 65, wherein the extrudable secondary aluminum scrap composition comprises an AA6063 alloy.

Aspect 67 provides the method of any of Aspects 51-66, wherein the alloying element composition is in a range of from about 5 to about 60 wt % of the feedstock.

Aspect 68 provides the method of any of Aspects 51-67, further comprising at least one of:

• • a pre-consumer scrap composition;
  • a post-consumer scrap composition differing in chemical composition to the extrudable floated fragmentizer aluminum scrap composition;
  • a primary aluminum; or
  • a mixture of at least two thereof.

Aspect 69 provides the method Aspect 68, wherein the pre-consumer scrap composition is a pre-consumer aluminum scrap material.

Aspect 70 provides the method of any of Aspects 68 or 69, wherein the aluminum scrap composition, the alloying element composition, the post-consumer scrap, and the pre-consumer scrap composition independently range from about 1 wt % to about 99 wt % of the extrusion feedstock.

Aspect 71 provides the method of any of Aspects 68-70, wherein the aluminum scrap composition, the alloying element composition, the post-consumer scrap, and the pre-consumer scrap composition independently range from about 5 wt % to about 95 wt % of the extrusion feedstock.

Aspect 72 provides the method of any of Aspects 68-71, wherein the aluminum scrap composition, the alloying element composition, the post-consumer scrap, and the pre-consumer scrap composition independently range from about 20 wt % to about 80 wt % of the extrusion feedstock.

Aspect 73 provides the method of any of Aspects 68-72, wherein the aluminum scrap composition, the alloying element composition, the post-consumer scrap, and the pre-consumer scrap composition independently range from about 25 wt % to about 75 wt % of the extrusion feedstock.

Aspect 74 provides the method of any of Aspects 68-73, wherein the aluminum scrap composition, the alloying element composition, and the pre-consumer scrap composition independently range from about 1 wt % to about 99 wt % of the extrusion feedstock.

Aspect 75 provides the method of any of Aspects 68-74, wherein the aluminum scrap composition, the alloying element composition, and the pre-consumer scrap composition independently range from about 5 wt % to about 95 wt % of the extrusion feedstock.

Aspect 76 provides the method of any of Aspects 68-75, wherein aluminum scrap composition, the alloying element composition, and the pre-consumer scrap composition independently range from about 20 wt % to about 80 wt % of the extrusion feedstock.

Aspect 77 provides the method of any of Aspects 68-76, wherein aluminum scrap composition, the alloying element composition, and the pre-consumer scrap composition independently range from about 25 wt % to about 75 wt % of the extrusion feedstock.

Aspect 78 provides the method of any of Aspects 68-77, wherein the aluminum scrap composition, the alloying element composition, and the pre-consumer scrap composition each comprise about 50% of the extrusion feedstock.

Aspect 79 provides the method of any of Aspects 68-78, wherein the post-consumer scrap composition, the alloying element composition, and the aluminum scrap composition, independently range from about 1 wt % to about 99 wt % of the extrusion feedstock.

Aspect 80 provides the method of any of Aspects 68-79, wherein the post-consumer scrap composition, the alloying element composition, and the aluminum scrap composition independently range from about 5 wt % to about 95 wt % of the extrusion feedstock.

Aspect 81 provides the method of any of Aspects 68-80, wherein the post-consumer scrap composition, the alloying element composition, and the aluminum scrap composition independently range from about 20 wt % to about 80 wt % of the extrusion feedstock.

Aspect 82 provides the method of any of Aspects 68-81, wherein the post-consumer scrap composition, the alloying element composition, and the aluminum scrap composition independently range from about 25 wt % to about 75 wt % of the extrusion feedstock.

Aspect 83 provides the method of any of Aspects 68-82, wherein the post-consumer scrap composition, the alloying element composition, and the aluminum scrap composition each comprise about 50 wt % of the extrusion feedstock.

Aspect 84 provides the method of any of Aspects 51-83, wherein the feedstock is not homogenized.

Aspect 85 provides the method of any of Aspects 51-84, wherein at least the extrudable floated fragmentizer aluminum scrap composition and the alloying element composition are homogenized.

Aspect 86 provides the method of any of Aspects 51-85, wherein the feedstock is a billet.

Aspect 87 provides the method of any of Aspects 51-86, wherein the shear assisted extrusion device forms a high-performance alloy having a refined microstructure relative to a corresponding high-performance alloy that is not extruded by a shear assisted extrusion device.

Aspect 88 provides the method of Aspect 87, wherein the refined microstructure comprises an average grain size that is smaller in at least one dimension relative to the corresponding non-extruded product.

Aspect 89 provides the method of Aspect 88, wherein the refined microstructure comprises an average grain length that is smaller than an average grain length of the corresponding non-extruded product.

Aspect 90 provides the method of any of Aspects 87-89, wherein the impurities present in the refined microstructure are broken down to smaller pieces relative to the impurities in the corresponding non-extruded product.

Aspect 91 provides the method of any of Aspects 51-90, wherein an average grain length of the present of an extruded product of the extrusion feedstock is less than about 10 μm.

Aspect 92 provides the method of any of Aspects 51-91, wherein the shear assisted extrusion device disperses the alloying element composition to form a high-performance alloy.

Aspect 93 provides the method of any of Aspects 51-92, wherein the shear assisted extrusion device produces an alloy having phases formed that are not present in the extrusion feedstock.

Aspect 94 provides the method of any of Aspects 51-93, wherein the high-performance alloy produced by the shear assisted extrusion device exhibits increased mechanical properties compared to the aluminum scrap composition.

Aspect 95 provides The method of any of Aspects 51-94, wherein the alloying elements include silicon (Si) and magnesium (Mg) to form Mg₂Si precipitates that enhance the strength of the high-performance alloy.

Aspect 96 provides the method of any of Aspects 51-95, wherein the alloying elements include copper (Cu) to promote precipitation hardening and increase the yield strength of the high-performance alloy.

Aspect 97 provides the method of any of Aspects 51-96, wherein the alloying elements include zinc (Zn) and magnesium (Mg) in proportions that facilitate the formation of Mg(Zn,Cu)₂ phases within the high-performance alloy.

Aspect 98 provides the method of any of Aspects 51-97, wherein the alloying elements are added in stoichiometric amounts to achieve a specific alloy designation according to the Aluminum Association (AA) standards.

Aspect 99 provides the method of any of Aspects 51-98, wherein the alloying elements include a combination of manganese (Mn) and chromium (Cr) to improve the alloy's resistance to corrosion.

Aspect 100 provides the method of any of Aspects 51-99, further comprising introducing the feedstock into the shear assisted extrusion device, such that there is relative rotation between the extrusion die face and the feedstock.

Aspect 101 provides the method of any of Aspects 51-100, wherein the extrusion die face is a rotatable extrusion die face.

Aspect 102 provides the method of any of Aspects 51-101, wherein the extrusion die face comprises grooves configured to draw material into an aperture of the die.

Aspect 103 provides the method of any of Aspects 51-102, wherein the extrusion die face rotates at a rate of 10-1000 rotations per minute.

Aspect 104 provides the method of any of Aspects 51-103, wherein the extrusion die face rotates at a rate of 20-100 rotations per minute.

Aspect 105 provides a high-performance alloy formed by the method of any of Aspects 51-104.

Aspect 106 provides a high-performance alloy, comprising an extruded product of feedstock comprising:

• • at least 1 wt % of aluminum scrap composition comprising:
    • an extrudable floated fragmentizer aluminum scrap composition;
    • an extrudable fragmentizer aluminum scrap composition;
    • an extrudable secondary aluminum scrap composition; or
    • a mixture of at least two thereof; and
  • at least 0.01 wt % of an alloying element composition at least partially intermixed relative to the aluminum scrap composition, the alloying element composition comprising:
    • silicon in a range of from about 0.01 to about 15 wt % of the alloying element composition;
    • copper in a range of from about 0.01 to about 7 wt % of the alloying element composition;
    • iron in a range of from about 0.01 to about 6 wt % of the alloying element composition
    • magnesium in a range of from about 0.01 to about 10 wt % of the alloying element composition;
    • chromium in a range of from about 0.01 to about 5 wt % of the alloying element composition;
    • manganese in a range of from about 0.01 to about 5 wt % of the alloying element composition;
    • zinc in a range of from about 0.01 to about 8 wt % of the alloying element composition;
    • oxygen in a range of from about 0.01 to about 15 wt % of the alloying element composition;
    • a rare earth element in a range of from about 0.01 to about 15 wt % of the alloying element composition; ora mixture of at least two thereof.

Aspect 107 provides the high-performance alloy of Aspect 106, wherein the floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or both comprise an impurity, the impurity comprising at least one of:

• • silicon in a range of from about 0.3 wt % to about 10 wt % of the extrudable floated fragmentizer aluminum scrap composition;
  • copper in a range of from about 1 wt % to about 3 wt % of the extrudable floated fragmentizer aluminum scrap composition;
  • iron in a range of from about 0.2 wt % to about 2 wt % of the extrudable floated fragmentizer aluminum scrap composition;
  • magnesium in a range of from about 0.3 wt % to about 3 wt % of the extrudable floated fragmentizer aluminum scrap composition;
  • manganese in a range of from about 0.1 wt % to about 2 wt % of the extrudable floated fragmentizer aluminum scrap composition;
  • zinc in a range of from about 0.1 wt % to about 1 wt % of the extrudable floated fragmentizer aluminum scrap composition; or
  • a mixture of at least two thereof.

Aspect 108 provides the high-performance alloy of any of Aspects 106 or 107, wherein aluminum is at least 80 wt % of the aluminum scrap composition.

Aspect 109 provides the high-performance alloy of any of Aspects 106-108, wherein aluminum is at least 82 wt % of the aluminum scrap composition.

Aspect 110 provides the high-performance alloy of any of Aspects 106-109, wherein aluminum is in a range of from about 82 wt % to about 96 wt % of the aluminum scrap composition.

Aspect 111 provides the high-performance alloy of any of Aspects 106-110, wherein aluminum is in a range of from about 85 wt % to about 91 wt % of the extrudable floated fragmentizer aluminum scrap composition.

Aspect 112 provides the high-performance alloy of any of Aspects 107-111, wherein the impurity comprises at least one of:

• • silicon in a range of from about 2 wt % to about 10 wt % of the floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or both;
  • copper in a range of from about 1.6 wt % to about 3 wt % of the floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or both;
  • iron in a range of from about 0.3 wt % to about 2 wt % of the floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or both;
  • magnesium in a range of from about 0.7 wt % to about 3 wt % of the floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or both;
  • manganese in a range of from about 0.2 wt % to about 2 wt % of the floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or both;
  • zinc in a range of from about 0.4 wt % to about 2 wt % of the floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or both; or
  • a mixture of at least two thereof.

Aspect 113 provides the high-performance alloy of any of Aspects 107-112, wherein the impurity comprises silicon in a range of from about 0.3 wt % to about 10 wt % of the floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or both.

Aspect 114 provides the high-performance alloy of any of Aspects 107-113, wherein the impurity comprises copper in a range of from about 1 wt % to about 3 wt % of the floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or both.

Aspect 115 provides the high-performance alloy of any of Aspects 107-114, wherein the impurity comprises iron in a range of from about 0.2 wt % to about 2 wt % of the floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or both.

Aspect 116 provides the high-performance alloy of any of Aspects 107-115, wherein the impurity comprises magnesium in a range of from about 0.3 wt % to about 3 wt % of the floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or both.

Aspect 117 provides the high-performance alloy of any of Aspects 107-116, wherein the impurity comprises manganese in a range of from about 0.2 wt % to about 2 wt % of the floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or both.

Aspect 118 provides the high-performance alloy of any of Aspects 107-117, wherein the impurity comprises zinc in a range of from about 0.1 wt % to about 1 wt % of the floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or both.

Aspect 119 provides the high-performance alloy of any of Aspects 107-118, wherein the impurity comprises:

• • silicon in a range of from about 2 wt % to about 10 wt % of floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or both;
  • copper in a range of from about 1 wt % to about 3 wt % of the floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or both;
  • iron in a range of from about 0.2 wt % to about 2 wt % of floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or both;
  • magnesium in a range of from about 0.3 wt % to about 3 wt % of the floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or both; and
  • manganese in a range of from about 0.2 wt % to about 2 wt % of floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or both.

Aspect 120 provides the high-performance alloy of any of Aspects 106-119, wherein the extrudable secondary aluminum scrap composition comprises a 5xxx series aluminum alloy, a 6xxx series aluminum alloy, a 7xxx series aluminum alloy, or a mixture of at least two thereof.

Aspect 121 provides the high-performance alloy of Aspect 120, wherein the extrudable secondary aluminum scrap composition comprises an AA6063 alloy.

Aspect 123 provides the high-performance alloy of any of Aspects 106-121, wherein the alloying element composition is in a range of from about 5 to about 60 wt % of the feedstock.

Aspect 124 provides the high-performance alloy of any of Aspects 106-123, further comprising at least one of:

• • a pre-consumer scrap composition;
  • a post-consumer scrap composition differing in chemical composition to the extrudable floated fragmentizer aluminum scrap composition;
  • a primary aluminum; or
  • a mixture of at least two thereof.

Aspect 125 provides the high-performance alloy Aspect 124, wherein the pre-consumer scrap composition is a pre-consumer aluminum scrap material.

Aspect 126 provides the high-performance alloy of any of Aspects 124 or 125, wherein the aluminum scrap composition, the alloying element composition, the post-consumer scrap, and the pre-consumer scrap composition independently range from about 1 wt % to about 99 wt % of the extrusion feedstock.

Aspect 127 provides the high-performance alloy of any of Aspects 124-126, wherein the aluminum scrap composition, the alloying element composition, the post-consumer scrap, and the pre-consumer scrap composition independently range from about 5 wt % to about 95 wt % of the extrusion feedstock.

Aspect 128 provides the high-performance alloy of any of Aspects 124-127, wherein the aluminum scrap composition, the alloying element composition, the post-consumer scrap, and the pre-consumer scrap composition independently range from about 20 wt % to about 80 wt % of the extrusion feedstock.

Aspect 129 provides the high-performance alloy of any of Aspects 124-128, wherein the aluminum scrap composition, the alloying element composition, the post-consumer scrap, and the pre-consumer scrap composition independently range from about 25 wt % to about 75 wt % of the extrusion feedstock.

Aspect 130 provides the high-performance alloy of any of Aspects 124-129, wherein the aluminum scrap composition, the alloying element composition, and the pre-consumer scrap composition independently range from about 1 wt % to about 99 wt % of the extrusion feedstock.

Aspect 131 provides the high-performance alloy of any of Aspects 124-130, wherein the aluminum scrap composition, the alloying element composition, and the pre-consumer scrap composition independently range from about 5 wt % to about 95 wt % of the extrusion feedstock.

Aspect 132 provides the high-performance alloy of any of Aspects 124-131, wherein aluminum scrap composition, the alloying element composition, and the pre-consumer scrap composition independently range from about 20 wt % to about 80 wt % of the extrusion feedstock.

Aspect 133 provides the high-performance alloy of any of Aspects 124-132, wherein aluminum scrap composition, the alloying element composition, and the pre-consumer scrap composition independently range from about 25 wt % to about 75 wt % of the extrusion feedstock.

Aspect 134 provides the high-performance alloy of any of Aspects 124-133, wherein the aluminum scrap composition, the alloying element composition, and the pre-consumer scrap composition each comprise about 50% of the extrusion feedstock.

Aspect 135 provides the high-performance alloy of any of Aspects 124-134, wherein the post-consumer scrap composition, the alloying element composition, and the aluminum scrap composition, independently range from about 1 wt % to about 99 wt % of the extrusion feedstock.

Aspect 136 provides the high-performance alloy of any of Aspects 124-135, wherein the post-consumer scrap composition, the alloying element composition, and the aluminum scrap composition independently range from about 5 wt % to about 95 wt % of the extrusion feedstock.

Aspect 137 provides the high-performance alloy of any of Aspects 124-136, wherein the post-consumer scrap composition, the alloying element composition, and the aluminum scrap composition independently range from about 20 wt % to about 80 wt % of the extrusion feedstock.

Aspect 138 provides the high-performance alloy of any of Aspects 124-137, wherein the post-consumer scrap composition, the alloying element composition, and the aluminum scrap composition independently range from about 25 wt % to about 75 wt % of the extrusion feedstock.

Aspect 139 provides the high-performance alloy of any of Aspects 124-138, wherein the post-consumer scrap composition, the alloying element composition, and the aluminum scrap composition each comprise about 50 wt % of the extrusion feedstock.

Aspect 140 provides the high-performance alloy of any of Aspects 106-139, wherein the extrusion feedstock is extruded through a shear assisted extrusion device.

Aspect 141 provides the high-performance alloy of Aspect 140, wherein the shear assisted extrusion device forms a high-performance alloy having a refined microstructure relative to a corresponding high-performance alloy that is not extruded by a shear assisted extrusion device.

Aspect 142 provides the high-performance alloy of Aspect 141, wherein the refined microstructure comprises an average grain size that is smaller in at least one dimension relative to a corresponding non-extruded product.

Aspect 143 provides the high-performance alloy of any of Aspects 141 or 142, wherein the refined microstructure comprises an average grain length that is smaller than an average grain length of a corresponding non-extruded product.

Aspect 144 provides the high-performance alloy of any of Aspects 141-143, wherein the impurities present in the refined microstructure are broken down to smaller pieces relative to the impurities in a corresponding non-extruded product.

Aspect 145 provides the high-performance alloy of any of Aspects 141-144, wherein an average grain length of the extruded product of the extrusion feedstock is less than about 10 μm.

Aspect 146 provides the high-performance alloy of any of Aspects 141-145, wherein the shear assisted extrusion device disperses the alloying element composition to form a high-performance alloy.

Aspect 147 provides the high-performance alloy of any of Aspects 141-146, wherein the shear assisted extrusion device produces an alloy having phases formed that are not present in the extrusion feedstock.

Aspect 148 provides the high-performance alloy of any of Aspects 106-147, wherein the high-performance alloy produced by the shear assisted extrusion device increased mechanical properties compared to the aluminum scrap composition.

Aspect 149 provides the high-performance alloy of any of Aspects 106-148, wherein the alloying elements include silicon (Si) and magnesium (Mg) to form Mg₂Si precipitates that enhance the strength of the high-performance alloy.

Aspect 150 provides the high-performance alloy of any of Aspects 106-149, wherein the alloying elements include copper (Cu) to promote precipitation hardening and increase the yield strength of the high-performance alloy.

Aspect 151 provides the high-performance alloy of any of Aspects 106-150, wherein the alloying elements include zinc (Zn) and magnesium (Mg) in proportions that facilitate the formation of Mg(Zn,Cu)₂ phases within the high-performance alloy.

Aspect 152 provides the high-performance alloy of any of Aspects 106-151, wherein the alloying elements are added in stoichiometric amounts to achieve a specific alloy designation according to the Aluminum Association (AA) standards.

Aspect 153 provides the high-performance alloy of any of Aspects 106-152, wherein the alloying elements include a combination of manganese (Mn) and chromium (Cr) to improve the alloy's resistance to corrosion.

Claims

1. An extrusion feedstock comprising: at least 1 wt % of aluminum scrap composition comprising: an extrudable floated fragmentizer aluminum scrap composition;an extrudable fragmentizer aluminum scrap composition;an extrudable secondary aluminum scrap composition; ora mixture of at least two thereof; andat least 0.01 wt % of an alloying element composition at least partially intermixed relative to the aluminum scrap composition, the alloying element composition comprising: silicon in a range of from about 0.01 to about 15 wt % of the alloying element composition;copper in a range of from about 0.01 to about 7 wt % of the alloying element composition;iron in a range of from about 0.01 to about 6 wt % of the alloying element compositionmagnesium in a range of from about 0.01 to about 10 wt % of the alloying element composition;chromium in a range of from about 0.01 to about 5 wt % of the alloying element composition;manganese in a range of from about 0.01 to about 5 wt % of the alloying element composition;zinc in a range of from about 0.01 to about 8 wt % of the alloying element composition;oxygen in a range of from about 0.01 to about 15 wt % of the alloying element composition;a rare earth element in a range of from about 0.01 to about 15 wt % of the alloying element composition; ora mixture of at least two thereof.

2. The extrusion feedstock of claim 1, wherein aluminum is at least 80 wt % of the aluminum scrap composition.

3. The extrusion feedstock of claim 1, wherein the extrudable secondary aluminum scrap composition comprises a 5xxx series aluminum alloy, a 6xxx series aluminum alloy, a 7xxx series aluminum alloy, or a mixture of at least two thereof.

4. The extrusion feedstock of claim 3, wherein the extrudable secondary aluminum scrap composition comprises an AA6063 alloy.

5. The extrusion feedstock of claim 1, wherein the alloying element composition is in a range of from about 5 to about 60 wt % of the feedstock.

6. The extrusion feedstock of claim 1, further comprising at least one of: a pre-consumer scrap composition;a post-consumer scrap composition differing in chemical composition to the extrudable floated fragmentizer aluminum scrap composition;a primary aluminum; ora mixture of at least two thereof.

7. A method of forming a high-performance alloy, the method comprising: using a shear assisted extrusion device, providing relative rotation between an extrusion die face and a feedstock;applying a relative axial translating force between the extrusion die face and the feedstock sufficient to heat and plasticize, and mix the feedstock at an interface between the feedstock and the extrusion die face to form an alloy that is extruded through an aperture of the die;wherein, the feedstock comprises: at least 1 wt % of aluminum scrap composition comprising: an extrudable floated fragmentizer aluminum scrap composition;an extrudable fragmentizer aluminum scrap composition;an extrudable secondary aluminum scrap composition; ora mixture of at least two thereof; andat least 0.01 wt % of an alloying element composition at least partially intermixed relative to the aluminum scrap composition, the alloying element composition comprising:silicon in a range of from about 0.01 to about 15 wt % of the alloying element composition;copper in a range of from about 0.01 to about 7 wt % of the alloying element composition;iron in a range of from about 0.01 to about 6 wt % of the alloying element compositionmagnesium in a range of from about 0.01 to about 10 wt % of the alloying element composition;chromium in a range of from about 0.01 to about 5 wt % of the alloying element composition;manganese in a range of from about 0.01 to about 5 wt % of the alloying element composition;zinc in a range of from about 0.01 to about 8 wt % of the alloying element composition;oxygen in a range of from about 0.01 to about 15 wt % of the alloying element composition;a rare earth element in a range of from about 0.01 to about 15 wt % of the alloying element composition; or

8. The method of claim 7, wherein the extrudable secondary aluminum scrap composition comprises a 5xxx series aluminum alloy, a 6xxx series aluminum alloy, a 7xxx series aluminum alloy, or a mixture of at least two thereof.

9. A high-performance alloy, comprising an extruded product of feedstock comprising: at least 1 wt % of aluminum scrap composition comprising: an extrudable floated fragmentizer aluminum scrap composition;an extrudable fragmentizer aluminum scrap composition;an extrudable secondary aluminum scrap composition; ora mixture of at least two thereof; andat least 0.01 wt % of an alloying element composition at least partially intermixed relative to the aluminum scrap composition, the alloying element composition comprising: silicon in a range of from about 0.01 to about 15 wt % of the alloying element composition;copper in a range of from about 0.01 to about 7 wt % of the alloying element composition;iron in a range of from about 0.01 to about 6 wt % of the alloying element compositionmagnesium in a range of from about 0.01 to about 10 wt % of the alloying element composition;chromium in a range of from about 0.01 to about 5 wt % of the alloying element composition;manganese in a range of from about 0.01 to about 5 wt % of the alloying element composition;zinc in a range of from about 0.01 to about 8 wt % of the alloying element composition;oxygen in a range of from about 0.01 to about 15 wt % of the alloying element composition;a rare earth element in a range of from about 0.01 to about 15 wt % of the alloying element composition; or

10. The high-performance alloy of claim 9, wherein the shear assisted extrusion device forms a high-performance alloy having a refined microstructure relative to a corresponding high-performance alloy that is not extruded by a shear assisted extrusion device.

11. The high-performance alloy of claim 10, wherein the refined microstructure comprises an average grain size that is smaller in at least one dimension relative to a corresponding non-extruded product.

12. The high-performance alloy of claim 10, wherein the refined microstructure comprises an average grain length that is smaller than an average grain length of a corresponding non-extruded product.

13. The high-performance alloy of claim 10, wherein the impurities present in the refined microstructure are broken down to smaller pieces relative to the impurities in a corresponding non-extruded product.

14. The high-performance alloy of claim 10, wherein an average grain length of the extruded product of the extrusion feedstock is less than about 10 μm.

15. The high-performance alloy of claim 9, wherein the high-performance alloy is produced by the shear assisted extrusion device and has increased mechanical properties compared to the aluminum scrap composition.

16. The high-performance alloy of claim 9, wherein the alloying elements include silicon (Si) and magnesium (Mg) to form Mg2Si precipitates that enhance the strength of the high-performance alloy.

17. The high-performance alloy of claim 9, wherein the alloying elements include copper (Cu) to promote precipitation hardening and increase the yield strength of the high-performance alloy.

18. The high-performance alloy of claim 9, wherein the alloying elements include zinc (Zn) and magnesium (Mg) in proportions that facilitate the formation of Mg(Zn,Cu)2 phases within the high-performance alloy.

19. The high-performance alloy of claim 9, wherein the alloying elements are added in stoichiometric amounts to achieve a specific alloy designation according to the Aluminum Association (AA) standards.

20. The high-performance alloy of claim 9, wherein the alloying elements include a combination of manganese (Mn) and chromium (Cr) to improve the alloy's resistance to corrosion.