Chemical composition design in cast aluminum alloys for enhanced microstructure and functionality

Aluminium alloys are designed by adding specific alloying elements such as manganese, silicon, magnesium, to the base metal to achieve desired properties for culinary items. The study was focused on optimizing the chemical composition of cast aluminum alloys derived from recycled aluminum to enhance their microstructure, mechanical characteristics, and functionality. This study presents the chemical composition design of cast aluminum alloys, aiming to enhance their microstructure and mechanical properties. Energy-dispersive X-ray spectroscopy (EDS) analysis indicates that the Mg/Si ratio is 1.78 (Mg: 1.76 wt%, Si: 0.99 wt%). The development of Mg2Si precipitation is facilitated by such balance, and the amount of brittle primary Si phases is reduced as a result. Vickers hardness testing shows that the material is stable under load (average 35.1 ± 2.3 HV at 100–1000 gf) on the as-cast alloy prior to heat treatment and that the bulk integrity is consistent (43.4 HV ± 5.1 at 50 gf). The distribution of elements, necessary for enhancing material properties such as microstructure, chemical composition, bonding configuration, and interfacial adhesion, has been studied via EDS analysis. Furthermore, the low alloying element, Mn (0.09 atomic%), was dispersed to enhance solid-solution strengthening, thereby strengthening the grain boundary and improving interface bonding without reducing the ductility and thermal conductivity of the Al matrix. This alloy resulted in a significantly harder Al-alloy. Therefore, the improved Mg2Si dispersion can be used to make utensils that are more resistant to wear and damage and easier to manufacture by die casting, proving that composition-driven design is a better way to utilize the recycled aluminum.