In response to global warming, aluminum industry takes action to cut their green house gas (GHG) emissions. Regulation of CO2 emission in the automotive industry is being restricted worldwide. Recycling of aluminum enables saving energy and emitting low amount of carbon dioxide compared to the smelting from bauxite ores [1]. Scrap and chips, which contain impurities and Fe contents, are ubiquitous resources for recycled aluminium alloys. Fe-containing aluminum alloys are good candidates in order to develop recycled alloys. End-of-life products can be reproduced for new products by recycling and processing.

To date, lower Fe-containing alloys are favorable to obtain high quality properties by removing large quantities of Fe-intermetallic compounds (Fe-IMCs). Suitable alloying elements and heat treatment are required to neutralize the negative effect of Fe-IMCs on physical properties [2-3]. High Fe-containing aluminum alloys have not been paid attention to the aluminum industry because they are undesirable for alloy design.

 In this study, quantities of Fe intentionally increased up to 1 mass % to cause the formation of Fe-IMCs in the Al matrix. A Deformation-semisolid extrusion process was used to disperse Fe-IMCs and reduce grain size. Irregular Fe-IMCs were heterogeneously fragmented into pieces. Microstructure of as-extruded 1 Fe alloy is as shown in Fig. 1. It consists of fragmented Fe-IMCs, Si and others. Its influence on the mechanical properties was systematically investigated by several experimental techniques. Microstructure evolution of as-extruded 1 Fe alloy was monitored to track crack initiation and propagation using In-Situ tensile testing, and it still needs further study to gain a better understanding of damage evolution and tolerance with a focus on the effects of fragmented Fe-IMCs. Fracture and deformation mechanism of Fe-containing Al-Si-Cu-Mg alloy were characterized in this study.