A Comparative Analysis of AA6061 and AlSi10Mg Processed via Friction Stir Extrusion

The aim of this study is to investigate the different behaviours of two aluminium alloys—AA6061, an age-hardening alloy, and AlSi10Mg, a casting alloy—under Friction Stir Extrusion processing. Friction Stir Extrusion (FSE), a sustainable solid-state recycling method, eliminates the need for melting and minimizes energy consumption, promoting efficient material reuse. The sustainability of this process is reinforced by the use of AlSi10Mg derived from recycled powder no longer suitable for Laser Powder Bed Fusion (L-PBF) due to granulometric changes post-printing. The experimental campaign analysed the influence of FSE parameters on microstructure and mechanical properties, revealing alloy-specific responses. These findings highlight the potential of FSE for manufacturing high-performance materials with reduced environmental impact, advancing the circular economy in metal recycling and additive manufacturing.