A Review of the Properties and Potential of Melting and Smelting Slag-Reinforced Aluminum Matrix Composites (AMCs)

Amra, Rana. H; Awad, Ahmed H.; Elsabbagh, Ahmed M.; Taha, Mohamed A.

doi:10.21608/ejchem.2025.377999.11638

A Review of the Properties and Potential of Melting and Smelting Slag-Reinforced Aluminum Matrix Composites (AMCs)

Articles in Press

Document Type : Review Articles

Authors

¹ Ain Shans University

² Design and Production Department, Faculty of Engineering Ain Shams University, Cairo 11535, Egypt

³ Design and Production Department, Faculty of Engineering Ain Shams University, Cairo 11535, Egypt.

10.21608/ejchem.2025.377999.11638

Abstract

Metallurgical slag is a byproduct of industrial waste produced during the metallurgical industry's mineral smelting and metal production. It is a significant industrial solid waste that accumulates in large quantities, posing environmental and disposal challenges due to the continuous growth of metallurgical production worldwide. These challenges include environmental pollution, such as heavy metal leaching into groundwater, as the slag may contain toxic metals, and soil contamination, which threaten the ecosystem and human health. These pressing issues highlight the urgent need for sustainable solutions for the usage of slags and to exploit them in a value-added industry, which is the focus of this review. Slag is a promising hybrid ceramic material that can improve the metallurgical and mechanical properties of aluminum composites, replacing conventional reinforcing materials like silicon carbide (SiC) and titanium dioxide (TiO2). It is primarily based on an oxide-rich composition that includes iron oxides (FeO or Fe2O3), silica (SiO2), alumina (Al2O3), and limestone (CaO). In this review, the authors studied the potential of utilizing the crushed slag powder to develop aluminum metal matrix composites by analyzing a comprehensive range of studies, from the earliest to the most recent studies on ferrous slags (Electric arc furnace slag, Blast furnace slag, Induction furnace slag, Cupola furnace slag) and nonferrous slags (Copper slag and Ferrochrome slag), evaluating different processing techniques for incorporating slag powder into the aluminum alloy matrix. The processing technique of slag powder as a byproduct for application in metal matrix composites is reviewed. Microstructure, porosity, and mechanical properties of Al-Particulate slag metal matrix composites using the different slags are compared and correlated. However, there is variation in mechanical properties – attributed to differences in slag composition and particle size – emphasizing the necessity of standardized testing in order to optimize performance.

Overall, this review supports the utilization of metallurgical slags as sustainable particulate reinforcement in aluminum-based matrix composites (AMCs) and offers insights into enhancing their applications through material selection and processing management.

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