Recycling of materials industrial waste into a new composite alloy using sintering technique

• Strength Improvement – Adding 10 % and 20 % aluminum ash increased tensile strength by 15 % and 25 %, respectively. • Thermal Reduction – Aluminum ash significantly lowered the composite's thermal conductivity at high temperatures. • Comprehensive Analysis – Various tests examined mechanical, thermal, and microstructural properties. This work focuses on the process of recycling industrial waste through the sintering method to incorporate aluminum ash into a new composite alloy. The work aims to utilize aluminum A365 as the starting material, modified with aluminum ash containing different proportions of 10 %, 20 %, and 30 % wt., and a control aluminum alloy A365 without the ash. Various mechanical, microstructure, and synergistic properties of the composite were evaluated under several consecutive tests. Tensile strength, elongation, and fatigue life were assessed with the help of the Universal Testing Machine (UTM). The change in the surface chemistry of the new composite was characterized through Fourier Transform Infrared Spectroscopy (FTIR) analysis. Moreover, corrosion performance was studied using potentiostat equipment. Microtexture changes in the composite and its surface roughness were also investigated using Atomic Force Microscopy (AFM). The results demonstrated that using 10 % and 20 % aluminum ash content causes a significant enhancement in the mechanical properties of the alloys, with an increase in the tensile strength of 15 % and 25 %, respectively, compared to the base alloy. In addition, the use of 30 % ash slightly reduced the fatigue life of the composite compared to the base alloy, while the addition of 20 % ash was found to be the optimum content in terms of fatigue resistance.