Phase-field modeling of fracture in recycled aluminum alloys: Impact of scrap-induced particles on crack behavior

  • Schneider, Tom (TUD Dresden University of Technology)
  • Mohammed, Waleed (Max Planck Institute for Sustainable Material)
  • Raabe, Dierk (Max Planck Institute for Sustainable Material)
  • Kästner, Markus (TUD Dresden University of Technology)

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Recycling aluminum (Al) scrap can reduce greenhouse gas emissions by over 90% compared to primary production [1], yet scrap-borne contaminants such as iron (Fe) and silicon (Si) lead to brittle intermetallic particles that compromise mechanical performance [2]. These microstructural features serve as preferential sites for crack initiation and significantly influence crack propagation paths in wrought Al alloys. We present an FFT-based phase-field fracture framework [3] to quantify the effects of scrap-induced particles on fracture mechanics. The computational approach integrates experimentally characterized microstructures, reconstructed from micrographs and 3D sectional slicing data, to generate statistically representative unit cells. Ensemble simulations capture the statistical variability in fracture response arising from microstructural heterogeneities. Results demonstrate that brittle particles act as stress concentrators, triggering premature crack initiation and deflecting crack paths. Through systematic correlation analysis, we quantify relationships between particle morphology, distribution, and macroscopic fracture properties including strength and ductility. The findings demonstrate damage mechanisms in scrap-contaminated alloys and provide computational tools for optimizing recycling strategies to enhance mechanical performance. References ---------- [1] Raabe et al. 2022, Progress in Materials Science 128, pp. 100947, doi:10.1016/j.pmatsci.2022.100947 [2] Mohammed, W., Chen, X., Ponge, D., and Raabe, D. 2025, Acta Materialia 289, pp. 120932, doi:10.1016/j.actamat.2025.120932 [3] Schneider, T. and Kästner, M. 2025, Fatigue & Fracture of Engineering Materials & Structures 48, pp. 1782-1805, doi:10.1111/ffe.14553