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The impact of high shear melt conditioning on the morphology and distribution of Fe intermetallic compounds was investigated in the processing of recycled AA6111 alloy by the twin roll casting process.The optical and scanning electron microscope (SEM) micrograph studies were carried out on twin roll casting (TRC) and melt conditioning twin roll casting (MC-TRC) samples. The microstructural analysis showed fine and uniformly distributed Fe-rich intermetallic phases for MC-TRC strips compared with the TRC strips. There was a significant improvement in the mechanical properties of MC-TRC strips after applying melt conditioning. The as-cast MC-TRC samples showed 18.7%, 19.2% and 9.8% increases in elongation, yield strength and ultimate tensile strength, respectively, in the longitudinal direction, while in the transverse section, the MC-TRC samples showed 32.3%, 2.2% and 3.8% increases in elongation, yield strength and ultimate tensile strength, respectively.

Fe-Rich Intermetallic Formation and Mechanical Properties of Recycled AA6111 Alloy Strips Produced by Melt Conditioning Twin Roll Casting