Material Characterization and Remelting Behavior of Recycled Aluminum Briquettes Produced from Machining Chips

This study presents a material-level characterization of recycled aluminum briquettes produced by cold pressing Al–Si–Mg machining chips and investigates their behavior during subsequent remelting. The study evaluates density, porosity, chemical composition, and metallurgical yield before and after remelting, with the aim of assessing material-related prerequisites for potential metallurgical reuse applications. The cold-pressed briquette (Sample A) exhibited a bulk density of 2.29 g·cm−3 and an estimated porosity of 14.6%, attributed mainly to intergranular voids and residual surface contaminants. After melting and resolidification (Sample B), the density increased to 2.388 g·cm−3, while the estimated porosity decreased to 10.9%. Handheld ED-XRF analysis indicated no substantial compositional variation within the instrumental uncertainty range after remelting. SEM–EDS observations revealed Al-rich surface regions containing minor oxygen contributions associated with naturally formed surface oxides, while no pronounced intermetallic features were observed at the analyzed surface locations. The remelting process achieved a metallurgical yield of 94.2% with low dross generation. The results indicate that appropriately preprocessed and compacted aluminum machining chips can form mechanically stable briquettes with favorable remelting characteristics and potential applicability in secondary metallurgical processing. However, the present study does not evaluate deoxidation efficiency under molten steel conditions, which remains a subject for future investigation.