In the present study, high-throughput CALPHAD calculations are performed to obtain the phase equilibria and solidification properties of an as-cast aluminum alloy containing Si, Cu, Fe, Zn, Mn and Mg. The appropriate alloy compositions were reversely designed to optimize the solidification interval, promote eutectic solidification of Si and Fe-rich phases, and avoid the formation of primary intermetallic compounds, and the overall reduction of other type of intermetallic compounds. The alloy was developed entirely from post-consumer scrap by two-step simple low-cost gravity casting technology that is easily scalable. To validate the CALPHAD-guided design, the microstructure and mechanical properties of the developed alloy were studied. The developed alloy successfully demonstrated the feasibility of creating alloys from post-consumer scrap that meet industry standards, using only adjusting elements, grain refiners and modifiers. Consequently, this study provides a viable approach to increase the scrap recycling rate and contributes to the industrialization of aluminum castings with a low carbon footprint.
