Methods for producing 2024 and 7075 aluminum alloys by recycling waste aircraft aluminum alloys

Abstract

The present invention relates to techniques for producing 2024 and 7075 aluminum alloys by recycling waste aircraft aluminum alloys, which belong to technical fields for circular economy. The present invention develops techniques for obtaining the 2024 and 7075 aluminum alloys by subjecting waste aircraft aluminum alloys as raw materials to pretreatment, smelting, impurity removal, melt ingredient assay, ingredient adjustment, refining, and casting. Through utilizing the waste package aluminum alloys and the waste aluminum pop-top cans to adjust the ingredients, the waste aircraft aluminum alloys would be recycled at a lower cost without downgrading. The present invention has some advantages, such as low cost, and applicability for industrial production, as well as prominent economic benefit.

Claims

1. A method for producing 2024 and 7075 aluminum alloys by recycling waste aircraft aluminum alloys, comprising: subjecting the waste aircraft aluminum alloys to a pretreatment by removing polymers and composite materials by air elutriation; smelting the pretreated waste aircraft aluminum alloys until complete melting at a smelting temperature of 700° C. to 800° C.; purifying aluminum liquid using a foam ceramic filter plate having a pore diameter of 10 ppi to separate the impurities not molten in the aluminum liquid, wherein the impurities not molten in the aluminum comprise carbon fiber; testing the ingredients in the aluminum liquid, and comparing the ingredients with target aluminum alloy ingredients; and adjusting the ingredients in the aluminum liquid using other waste aluminum alloys and interalloys; purifying the aluminum liquid using a foam ceramic filter plate having a pore diameter of 20 ppi to separate the impurities not molten in the aluminum liquid; refining the aluminum liquid by adding a refining agent and a degasifier to form a refined aluminum liquid; and then purifying the refined aluminum liquid twice using foam ceramic filter plates having pore diameters of 40 ppi and 60 ppi, respectively, to separate substances not molten in the refined aluminum liquid; and casting the refined aluminum liquid to obtain the aluminum alloys with target ingredients.

2. The method for producing 2024 and 7075 aluminum alloys by recycling waste aircraft aluminum alloys according to claim 1, characterized in that: the other waste aluminum alloys comprise paint-removed waste aluminum pop-top cans and waste package aluminum alloys.

3. The method for producing 2024 and 7075 aluminum alloys by recycling waste aircraft aluminum alloys according to claim 1, characterized in that: filtered substances not molten while purifying the refined aluminum liquid using the foam ceramic filter plate having pore diameter of 60 ppi are waste aircraft aluminum alloy raw materials and inorganic coating materials adhered on the waste aluminum alloy raw materials.

4. The method for producing 2024 and 7075 aluminum alloys by recycling waste aircraft aluminum alloys according to claim 1, wherein the pretreatment of waste aircraft aluminum alloys further comprises breaking.

5. The method for producing 2024 and 7075 aluminum alloys by recycling waste aircraft aluminum alloys according to claim 1, wherein the pretreatment of waste aircraft aluminum alloys further comprises iron removal by magnetic separation.

6. The method for producing 2024 and 7075 aluminum alloys by recycling waste aircraft aluminum alloys according to claim 1, wherein the pretreatment of waste aircraft aluminum alloys further comprises removal of heavy metals by flotation.

7. The method for producing 2024 and 7075 aluminum alloys by recycling waste aircraft aluminum alloys according to claim 1, wherein the pretreatment of waste aircraft aluminum alloys further comprises removal of glass by eddy current sorting.

8. The method for producing 2024 and 7075 aluminum alloys by recycling waste aircraft aluminum alloys according to claim 1, wherein the pretreated waste aircraft aluminum alloys are smelted at a temperature of about 750° C.

9. A method, comprising: collecting raw materials comprising waste aircraft aluminum alloys; pretreating the waste aluminum aircraft raw materials by removing polymers and composite materials by air elutriation; smelting the pretreated waste aluminum aircraft raw materials to a liquid state; filtering the liquid to remove solid carbon fiber impurities using a foam ceramic filter plate; assaying the filtered liquid to determine the elemental composition of the melt; adjusting the metal element content of the melt through addition of aluminum alloys; filtering, refining, and purifying the adjusted melt by using a first foam ceramic filter plate, a refining agent, and a degasifier; repeating filtering the adjusted melt by using a second foam ceramic filter plate having pores having a diameter smaller than a diameter of pores of the first foam ceramic filter plate; and casting the purified liquid alloy to obtain aluminum alloy ingots.

10. The method of claim 9, wherein the aluminum alloy is a 7075 aluminum alloy comprising Cu, Zn, Mg, Mn, Cr, Si, Fe, Ti, or combination(s) thereof.

11. The method of claim 9, wherein the aluminum alloy is a 2024 aluminum alloy comprising Cu, Zn, Mg, Mn, Cr, Si, Fe, Ti, or combination(s) thereof.

12. The method of claim 9, wherein the pretreated waste aluminum aircraft raw materials are smelted at a temperature of about 700° C. to about 800° C.

13. The method of claim 9, wherein the pretreated waste aluminum aircraft raw materials are smelted at a temperature of about 750° C.

14. The method of claim 9, wherein the metal element content is adjusted by adding paint-removed waste aluminum pop-top cans or waste package aluminum alloys.

15. The method of claim 9, wherein the foam ceramic filter plate has a pore diameter of about 10 ppi to about 60 ppi.

16. The method of claim 1, wherein the aluminum alloys comprise an element selected from the group consisting of Cu, Zn, Mg, Mn, Cr, Si, Fe, Ti, and combinations thereof.

17. The method of claim 14, wherein the metal element content is adjusted by adding paint-removed waste aluminum pop-top cans.

18. The method of claim 14, wherein the metal element content is adjusted by adding waste package aluminum alloys.

19. The method of claim 15, wherein the foam ceramic filter plate has a pore diameter of about 20 ppi to about 60 ppi.

20. The method of claim 19, wherein the foam ceramic filter plate has a pore diameter of about 40 ppi to about 60 ppi.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1. Flow Chart of the process for recycling waste aircraft aluminum alloys.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

(2) The present invention will now be further described in detail with reference to the following Examples, but it is not limited to the following Examples.

Example 1

(3) Production of 7075 Aluminum Alloy by Recycling Waste Aircraft Aluminum Alloys (1) pretreatment: the waste aircraft aluminum alloys are subjected to breaking, iron removal by magnetic separation, removal of heavy metals by flotation, removal of polymers and composite materials by air elutriation, removal of glass by eddy current sorting, and the like; (2) smelting: the pretreated waste aircraft aluminum alloys are smelt till complete melting at a smelting temperature of 700° C.; (3) impurity removal: the aluminum liquid is purified using foam ceramic filter plate having a pore diameter of 10 ppi to separate the impurities not molten in the aluminum liquid; (4) ingredient adjustment: after the removal of impurities, two samples are taken from different parts of the aluminum melt for the ingredient assay.

(4) The ingredients in the standard 7075 aluminum alloy, the waste package aluminum alloys as ingredient adjustment agents, and the aluminum melt upon the impurity removal in “GB/T3190-2008 deformation aluminum and aluminum alloy ingredients” are shown in Table 1.

(5) TABLE-US-00001 TABLE 1 Table for the comparison of the aluminum alloy ingredients prior to ingredient proportioning and the 7075 aluminum alloy ingredients Cu Zn Mg Mn Cr Si Fe Ti Standard 7075 1.2-2.0 5.1-6.1 2.1-2.9 <0.3 0.18-0.3 <0.4 <0.5 <0.2 aluminum alloy Waste package <0.15 <0.25 4.0-5.0 0.2-0.5 <0.10 <0.20 <0.35 <0.10 aluminum alloys Melt ingredients 2.378 2.385 1.286 0.325 0.078 0.26 0.227 0.027

(6) Through the comparison of the aluminum alloy melt ingredients prior to ingredient adjustment and the standard 7075 aluminum alloy ingredients, it can be seen that the contents of Cu and Mn are excessive, while the contents of Zn, Mg, and Cr are insufficient. After calculation, 25% the paint-removed waste package aluminum alloys, 1.6% aluminum-chromium alloy, 3.5% metallic zinc and 1% aluminum-magnesium alloy are added into the melt, and well stirred. After the added materials are completely molten, two samples are taken from different parts of the aluminum melt for the ingredient assay. The comparison of adjusted aluminum melt ingredients and the standard 7075 aluminum alloy ingredients is shown in Table 2, and then the aluminum melt ingredients have already met the requirements for the standard 7075 aluminum alloy.

(7) TABLE-US-00002 TABLE 2 Table for the comparison of the melt ingredients upon adjustment and the standard 7075 alloy ingredients Cu Zn Mg Mn Cr Si Fe Ti Standard 7075 1.2-2.0 5.1-6.1 2.1-2.9 <0.3 0.18-0.3 <0.4 <0.5 <0.2 aluminum alloy Melt ingredients 1.622 5.584 2.498 0.272 0.238 0.22 0.263 0.019 (5) filtration: the aluminum liquid is purified using foam ceramic filter plate having a pore diameter of 20 ppi to separate the impurities not molten in the aluminum liquid; (6) refining and purification: the aluminum liquid is refined by adding a refining agent and a degasifier, and the refined aluminum liquid is placed for a period; the aluminum liquid is then purified twice using foam ceramic filter plates having pore diameters of 40 ppi and 60 ppi to separate the substances not molten in the aluminum liquid, respectively. (7) casting: after refining and removing impurities, the aluminum liquid is casted to obtain the 7075 aluminum alloy ingot.

Example 2

(8) Production of 2024 Aluminum Alloy by Recycling Waste Aircraft Aluminum Alloys (1) pretreatment: the waste aircraft aluminum alloys are subjected to breaking, iron removal by magnetic separation, removal of heavy metals by flotation, removal of polymers and composite materials by air elutriation, removal of glass by eddy current sorting, and the like; (2) smelting: the pretreated waste aircraft aluminum alloys are smelt till complete melting at a smelting temperature of 800° C.; (3) impurity removal: the aluminum liquid is purified using foam ceramic filter plate having a pore diameter of 10 ppi to separate the impurities not molten in the aluminum liquid; (4) ingredient adjustment: after the removal of impurities, two samples are taken from different parts of the aluminum melt for the ingredient assay.

(9) The ingredients in the standard 2024 aluminum alloy, the waste aluminum pop-top cans as ingredient adjustment agents, and the aluminum melt upon the impurity removal in “GB/T3190-2008 deformation aluminum and aluminum alloy ingredients” are shown in Table 3.

(10) TABLE-US-00003 TABLE 3 Table for the comparison of the aluminum alloy ingredients prior to ingredient proportioning and the 2024 aluminum alloy ingredients Cu Zn Mg Mn Cr Si Fe Ti Standard 2024 3.8-4.9 <0.25 1.2-1.8 0.3-0.9 <0.1 <0.5 <0.5 <0.15 aluminum alloy the waste 0.05-0.25 <0.25 0.8-1.3 0.8-1.4 — <0.60 <0.80 <0.10 aluminum pop-top cans Melt ingredients 3.752 1.543 1.368 0.532 0.043 0.20 0.213 0.028

(11) Through the comparison of the aluminum alloy melt ingredients prior to ingredient adjustment and the standard 2024 aluminum alloy ingredients, it can be seen that the content of Zn is excessive, while the content of Cu is insufficient. After calculation, 650% paint-removed waste aluminum pop-top can sheets, 1.6% aluminum-chromium alloy, 22.5% metallic copper and 10% aluminum-magnesium alloy are added into the melt, and well stirred. After the added materials are completely molten, two samples are taken from different parts of the aluminum melt for the ingredient assay. The comparison of adjusted aluminum melt ingredients and the standard 2024 aluminum alloy ingredients is shown in Table 4, and then the aluminum melt ingredients have already met the requirements for the standard 2024 aluminum alloy.

(12) TABLE-US-00004 TABLE 4 Table for the comparison of the melt ingredients upon adjustment and the standard 2024 alloy ingredients Cu Zn Mg Mn Cr Si Fe Ti Standard 2024 3.8-4.9 <0.25 1.2-1.8 0.3-0.9 <0.1 <0.5 <0.5 <0.15 aluminum alloy Melt ingredients 4.298 0.224 1.512 0.638 0.032 0.23 0.403 0.032 (5) filtration: the aluminum liquid is purified using foam ceramic filter plate having a pore diameter of 20 ppi to separate the impurities not molten in the aluminum liquid; (6) refining and purification: the aluminum liquid is refined by adding a refining agent and a degasifier, and the refined aluminum liquid is placed for a period; the aluminum liquid is then purified twice using foam ceramic filter plates having pore diameters of 40 ppi and 60 ppi to separate the substances not molten in the aluminum liquid, respectively. (7) casting: after refining and removing impurities, the aluminum liquid is casted to obtain the 2024 aluminum alloy ingot.

Example 3

(13) Production of 7075 Aluminum Alloy by Recycling Waste Aircraft Aluminum Alloys

(14) (1) pretreatment: the waste aircraft aluminum alloys are subjected to breaking, iron removal by magnetic separation, removal of heavy metals by flotation, removal of polymers and composite materials by air elutriation, removal of glass by eddy current sorting, and the like; (2) smelting: the pretreated waste aircraft aluminum alloys are smelt till complete melting at a smelting temperature of 750° C.; (3) impurity removal: the aluminum liquid is purified using foam ceramic filter plate having a pore diameter of 10 ppi to separate the impurities not molten in the aluminum liquid; (4) ingredient adjustment: after the removal of impurities, two samples are taken from different parts of the aluminum melt for the ingredient assay.

(15) The ingredients in the standard 7075 aluminum alloy, the waste package aluminum alloys as ingredient adjustment agents, and the aluminum melt upon the impurity removal in “GB/T3190-2008 deformation aluminum and aluminum alloy ingredients” are shown in Table 5.

(16) TABLE-US-00005 TABLE 5 Table for the comparison of the aluminum alloy ingredients prior to ingredient proportioning and the 7075 aluminum alloy ingredients Cu Zn Mg Mn Cr Si Fe Ti Standard 7075 1.2-2.0 5.1-6.1 2.1-2.9 <0.3 0.18-0.3 <0.4 <0.5 <0.2 aluminum alloy Melt ingredients 2.138 3.012 1.375 0.295 0.094 0.25 0.245 0.025 Waste package <0.15 <0.25 4.0-5.0 <0.15 <0.15 <0.20 <0.35 <0.10 aluminum alloys

(17) Through the comparison of the aluminum alloy melt ingredients prior to ingredient adjustment and the standard 7075 aluminum alloy ingredients, it can be seen that the contents of Cu and Mn are excessive, while the contents of Zn, Mg, and Cr are insufficient. After calculation, 25% the paint-removed waste package aluminum alloys, 2% aluminum-chromium alloy, 4% metallic zinc and 1% aluminum-magnesium alloy are added into the melt, and well stirred. After the added materials are completely molten, two samples are taken from different parts of the aluminum melt for the ingredient assay. The comparison of adjusted aluminum melt ingredients and the standard 7075 aluminum alloy ingredients is shown in Table 6, and then the aluminum melt ingredients have already met the requirements for the standard 7075 aluminum alloy.

(18) TABLE-US-00006 TABLE 6 Table for the comparison of the melt ingredients upon adjustment and the standard 7075 alloy ingredients Cu Zn Mg Mn Cr Si Fe Ti Standard 7075 1.2-2.0 5.1-6.1 2.1-2.9 <0.3 0.18-0.3 <0.4 <0.5 <0.2 aluminum alloy Melt ingredients 1.596 5.828 2.597 0.268 0.257 0.25 0.295 0.021 (5) filtration: the aluminum liquid is purified using foam ceramic filter plate having a pore diameter of 20 ppi to separate the impurities not molten in the aluminum liquid; (6) refining and purification: the aluminum liquid is refined by adding a refining agent and a degasifier, and the refined aluminum liquid is placed for a period; the aluminum liquid is then purified twice using foam ceramic filter plates having pore diameters of 40 ppi and 60 ppi to separate the substances not molten in the aluminum liquid, respectively. (7) casting: after refining and removing impurities, the aluminum liquid is casted to obtain the 7075 aluminum alloy ingot.

Example 4

(19) Production of 2024 Aluminum Alloy by Recycling Waste Aircraft Aluminum Alloys (1) pretreatment: the waste aircraft aluminum alloys are subjected to breaking, iron removal by magnetic separation, removal of heavy metals by flotation, removal of polymers and composite materials by air elutriation, removal of glass by eddy current sorting, and the like; (2) smelting: the pretreated waste aircraft aluminum alloys are smelt till complete melting at a smelting temperature of 750° C.; (3) impurity removal: the aluminum liquid is purified using foam ceramic filter plate having a pore diameter of 10 ppi to separate the impurities not molten in the aluminum liquid; (4) ingredient adjustment: after the removal of impurities, two samples are taken from different parts of the aluminum melt for the ingredient assay.

(20) The ingredients in the standard 2024 aluminum alloy, the waste aluminum pop-top cans as ingredient adjustment agents, and the aluminum melt upon the impurity removal in “GB/T3190-2008 deformation aluminum and aluminum alloy ingredients” are shown in Table 7.

(21) TABLE-US-00007 TABLE 7 Table for the comparison of the aluminum alloy ingredients prior to ingredient proportioning and the 2024 aluminum alloy ingredients Cu Zn Mg Mn Cr Si Fe Ti Standard 2024 3.8-4.9 <0.25 1.2-1.8 0.3-0.9 <0.1 <0.5 <0.5 <0.15 aluminum alloy the aluminum <0.25 <0.25 0.8-1.3 1.0-1.5 — <0.30 <0.70 <0.10 waste pop-top cans Melt ingredients 4.312 0.22 1.498 0.641 0.036 0.20 0.385 0.028

(22) Through the comparison of the aluminum alloy melt ingredients and the standard 2024 aluminum alloy ingredients prior to ingredient adjustment, it can be seen that the content of Zn is excessive, while the content of Cu is insufficient. After calculation, 650% paint-removed waste aluminum pop-top can sheets, 1.5% aluminum-chromium alloy, 23% metallic copper and 10% aluminum-magnesium alloy are added into the melt, and well stirred. After the added materials are completely molten, two samples are taken from different parts of the aluminum melt for the ingredient assay. The comparison of adjusted aluminum melt ingredients and the standard 2024 aluminum alloy ingredients is shown in Table 8, and then the aluminum melt ingredients have already met the requirements for the standard 2024 aluminum alloy.

(23) TABLE-US-00008 TABLE 8 Table for the comparison of the melt ingredients upon adjustment and the standard 2024 alloy ingredients Cu Zn Mg Mn Cr Si Fe Ti 2024 3.8-4.9 <0.25 1.2-1.8 0.3-0.9 <0.1 <0.5 <0.5 <0.15 aluminum alloy Melt ingredients 4.312 0.22 1.498 0.641 0.036 0.20 0.385 0.028 (5) filtration: the aluminum liquid is purified using foam ceramic filter plate having a pore diameter of 20 ppi to separate the impurities not molten in the aluminum liquid; (6) refining and purification: the aluminum liquid is refined by adding a refining agent and a degasifier, and the refined aluminum liquid is placed for a period; the aluminum liquid is then purified twice using foam ceramic filter plates having pore diameters of 40 ppi and 60 ppi to separate the substances not molten in the aluminum liquid, respectively. (7) casting: after refining and removing impurities, the aluminum liquid is casted to obtain the 2024 aluminum alloy ingot.