Fracture and Structural Integrity e-ISSN 1971-8993 Open access
SI: From Microcracks to Structural Failure: Emerging Challenges in Fracture and Structural Integrity Vol. 20, No. 77 (2026)

Study of the influence of recycling aluminum on the cyclic material behavior for chill cast AlSi7Mg0.3

Author and affiliation details
  • Christoph Bleicher Corresponding author Fraunhofer Institute for Structural Durability and System Reliability LBF, Germany ORCID iD0000-0002-0874-9548 christoph.bleicher@lbf.fraunhofer.de
  • Ahmad Qaralleh Fraunhofer Institute for Structural Durability and System Reliability LBF, Germany ORCID iD0009-0009-9043-1720
  • Sascha Fliegener Fraunhofer Institute for Mechanics of Materials IWM, Germany
  • Silke Sommer Fraunhofer Institute for Mechanics of Materials IWM, Germany ORCID iD0009-0001-9375-560X
  • Robert Kleinhans Fraunhofer Institute for Casting, Composite and Processing Technology IGCV, Germany
  • Manuel Pintore Fraunhofer Institute for Casting, Composite and Processing Technology IGCV, Germany
DOI
10.3221/IGF-ESIS.77.16
Pages
265-280
Published
Licence
CC BY 4.0
Published inVol. 20, No. 77 (2026)Go to the issue

Abstract

Automotive industry and mechanical engineering strive to drastically reduce the carbon footprint of their products. This becomes increasingly important as aluminum usage grows for lightweight, efficient components. Nevertheless, cast aluminum products suffer from a lack of alloys bearing higher fractions of recycling content, though their availability is crucial. Using recycling aluminum in gravity die casting offers high potential for CO2 reduction, but the effect of increasing accompanying elements like Cu, Zn or Fe on cyclic material behavior has not been investigated yet.

Within the Fraunhofer internal research project "FutureCarProduction," the effects of secondary aluminum alloys on casting processes as well as fatigue and crash behavior of car body components are investigated. The aim is to find the optimal combination between manufacturing efficiency and durability regarding the alloy's potential to reduce carbon footprint and emissions during the product life cycle.

Based on alloy AlSi7Mg0.3 used in gravity die casting for car body components, three configurations — one primary alloy and two with accompanying elements — were cast and investigated through strain and stress-controlled tests. Results showed that additions of Fe and Zn lead to slightly increased cyclic and quasi-static material strength, whereas ductility was reduced.

Keywords

Article history

  1. ReceivedUntil the next stage: 38 days
  2. RevisedUntil the next stage: 15 days
  3. AcceptedUntil the next stage: 14 days
  4. Published

How to cite

APA

Bleicher, C., Qaralleh, A., Fliegener, S., Sommer, S., Kleinhans, R., & Pintore, M. (2026). Study of the influence of recycling aluminum on the cyclic material behavior for chill cast AlSi7Mg0.3. Fracture and Structural Integrity, 20(77), 265–280. https://doi.org/10.3221/IGF-ESIS.77.16

IEEE

C. Bleicher, A. Qaralleh, S. Fliegener, S. Sommer, R. Kleinhans, and M. Pintore, “Study of the influence of recycling aluminum on the cyclic material behavior for chill cast AlSi7Mg0.3,” Fracture and Structural Integrity, vol. 20, no. 77, pp. 265–280, 2026, doi: 10.3221/IGF-ESIS.77.16.

MLA

Bleicher, Christoph, et al. “Study of the influence of recycling aluminum on the cyclic material behavior for chill cast AlSi7Mg0.3.” Fracture and Structural Integrity, vol. 20, no. 77, 2026, pp. 265–280. https://doi.org/10.3221/IGF-ESIS.77.16.

Chicago

Bleicher, Christoph, Ahmad Qaralleh, Sascha Fliegener, Silke Sommer, Robert Kleinhans, and Manuel Pintore. 2026. “Study of the influence of recycling aluminum on the cyclic material behavior for chill cast AlSi7Mg0.3.” Fracture and Structural Integrity 20 (77): 265–280. https://doi.org/10.3221/IGF-ESIS.77.16.

Harvard

Bleicher, C., Qaralleh, A., Fliegener, S., Sommer, S., Kleinhans, R. and Pintore, M. (2026) ‘Study of the influence of recycling aluminum on the cyclic material behavior for chill cast AlSi7Mg0.3’, Fracture and Structural Integrity, 20(77), pp. 265–280. doi: 10.3221/IGF-ESIS.77.16.

Vancouver

Bleicher C, Qaralleh A, Fliegener S, Sommer S, Kleinhans R, Pintore M. Study of the influence of recycling aluminum on the cyclic material behavior for chill cast AlSi7Mg0.3. Fracture and Structural Integrity. 2026;20(77):265-280. doi:10.3221/IGF-ESIS.77.16

BibTeX

@article{bleicher2026, author = {Bleicher, Christoph and Qaralleh, Ahmad and Fliegener, Sascha and Sommer, Silke and Kleinhans, Robert and Pintore, Manuel}, title = {Study of the influence of recycling aluminum on the cyclic material behavior for chill cast AlSi7Mg0.3}, journal = {Fracture and Structural Integrity}, year = {2026}, volume = {20}, number = {77}, pages = {265--280}, doi = {10.3221/IGF-ESIS.77.16}, url = {https://doi.org/10.3221/IGF-ESIS.77.16}, issn = {1971-8993} }

RIS

TY - JOUR AU - Bleicher, Christoph AU - Qaralleh, Ahmad AU - Fliegener, Sascha AU - Sommer, Silke AU - Kleinhans, Robert AU - Pintore, Manuel TI - Study of the influence of recycling aluminum on the cyclic material behavior for chill cast AlSi7Mg0.3 JO - Fracture and Structural Integrity T2 - Fracture and Structural Integrity PY - 2026 DA - 2026/05/06 VL - 20 IS - 77 SP - 265 EP - 280 DO - 10.3221/IGF-ESIS.77.16 UR - https://doi.org/10.3221/IGF-ESIS.77.16 SN - 1971-8993 ER -

Licence

Creative Commons Attribution 4.0 International

May be shared and adapted, provided appropriate credit is given. Copyright © 2026 Christoph Bleicher, Ahmad Qaralleh, Sascha Fliegener, Silke Sommer, Robert Kleinhans, Manuel Pintore.

Copyright 
Authors are allowed to retain both the copyright and the publishing rights of their articles without restrictions.  

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