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Achieving superior mechanical properties of Al alloys with high content of Fe impurities is very challenging. Here, a feasible method was applied to accommodate high Fe content (∼2.2 wt.%) and obtain superior strength in an Al–5Mg 2 Si–2Mg–2Fe alloy by using additive manufacturing. Heterogeneous distribution of Fe, including a high number density of α-Al 12 (Fe,Mn) 3 Si particles distributed at the melting pool boundary and excessive Fe segregated along the cell boundaries that divided by Mg 2 Si eutectics, was verified as the beneficial factor for the alloy design and strength enhancement. In addition to the heterogeneous grains that contain fine cells, the interactions between dislocations and coherent Mg 2 Si eutectics and the α-Al 12 (Fe,Mn) 3 Si particles played an important role in improving the mechanical properties. This work represents a breakthrough in recycling high-strength Al alloys with extremely high Fe doping for green industrial application through additive manufacturing.

High-strength Al–5Mg 2 Si–2Mg–2Fe alloy with extremely high Fe content for green industrial application through additive manufacturing