Using Sustainable Manufacturing Process to Produce Solid Shaft from Al - Zn Alloys Chips and Copper Chips without Melting

Sustainable manufacturing process is a promising technology to reduce the waste and cost. Solid-state metal conversion is one of the most important processes to eliminate the required energy for melting and casting steps due its ability to produce solid shafts directly from solid chips. In this paper, direct recycling process for Al-Zn alloy and Copper chips generated through cutting processes is proposed. Cold pressing is utilized and the pressed chips are extruded with diameter of 12 mm and pressures of 10, 20, and 30 ton. This technique produce a significant deformation process leading to achieve proper material bonding. The results show high possibility to produce solid parts directly from solid chips without any melting and rolling process. The produced parts have mechanical properties closed to those obtained by the conventional forming technology. This method is relatively simple and demonstrate a clean recycling technology to reduce the waste and maximize the productivity.