Production of intermetallic-dominant Al–Fe–Si alloys via additive methods from scrap-based feedstock

Alloys in the Al-Fe-Si system are of significant interest due to their unique properties; however, their production poses a considerable technological challenge. In this study, an alloy with the nominal composition Al 60 Fe 30 Si 10 was synthesized using an additive manufacturing approach. Commercially available alloys were used as the starting materials. The resulting product was a homogeneous ingot exhibiting a uniform distribution of chemical elements. In the «as-prepared» state, the material demonstrated a duplex microstructure primarily composed of intermetallic phases, specifically a combination of β and θ phases, with randomly distributed face-centered cubic (FCC) aluminum. These results highlight the feasibility of recycling aluminum alloys and steel using industrial scrap instead of pure elemental metals, offering a substantial reduction in production costs.