Short Communication

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

Abylkas Saginov Karaganda Technical University, Karaganda, Kazakhstan

^* e-mail: Vi-ta.z@mail.ru

Received: 16 August 2024
Accepted: 8 October 2025

Abstract

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 Al₆₀Fe₃₀Si₁₀was 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.