Approaches to the design of recycling-tolerant Al-Zn-Mg alloys were formulated to be achieved via combined Ca, Fe, and Si, and appropriate solidification conditions and heat treatment. A CalPhaD calculation and experimental study were employed for analysis of the Al-8%Zn-3%Mg alloy doped with 1–2%Ca, 0.5%Fe, and 0.5%Si. The Al-8%Zn-3%Mg-1%Ca-0.5%Fe-0.5%Si (AlZnMg1CaFeSi) alloy was preliminarily found to be promising since it showed a high equilibrium solidus, and an as-cast structure including curved phases (Al), Al3Fe, Al2CaSi2, Al10CaFe2, and (Al, Zn)4Ca; favouring a further spheroidization response during a two-step annealing at 450 °C, 3 h + 520 °C, 3 h. Furthermore, the alloy showed an excellent age-hardening response (195 HV, T6), which did not yield the values of the base alloy and outperformed the values of the other experimental counterparts. Regarding feasibility, 80% reduction hot rolling was successfully conducted, as well as a brief comparison with commercial 6063 impurity-tolerant alloys. As it showed qualitatively similar structural patterns and Fe and Si alloying opportunities, the AlZnMg1CaFeSi alloy may serve as a sustainable basis for the further development of high-strength aluminum alloys tailored for manufacture from scrap materials.
Experimental study on the warm forming and quenching behavior for hot stamping of high-strength aluminum alloys