Production of Copper Ingots from Industrial Waste: An Innovative Solid-State Sintering Process with Microstructural and Crystallographic Analysis


BENKLİ Y. E., Korkmaz M. Ü.

Russian Journal of Non-Ferrous Metals, cilt.66, sa.4, ss.210-222, 2025 (SCI-Expanded) identifier identifier

  • Yayın Türü: Makale / Tam Makale
  • Cilt numarası: 66 Sayı: 4
  • Basım Tarihi: 2025
  • Doi Numarası: 10.1134/s1067821225600632
  • Dergi Adı: Russian Journal of Non-Ferrous Metals
  • Derginin Tarandığı İndeksler: Science Citation Index Expanded (SCI-EXPANDED), Scopus, Aerospace Database, Compendex, Geobase, INSPEC, Metadex
  • Sayfa Sayıları: ss.210-222
  • Anahtar Kelimeler: copper chips, energy efficiency, recycling, solid state sintering, sustainable production, zero-waste manufacturing
  • Atatürk Üniversitesi Adresli: Evet

Özet

Abstract: This study investigates the recycling of industrial waste copper chips generated during the processing of copper chips containing approximately 5% magnesium. An innovative patented modification was integrated with the classical solid-state sintering method to directly produce copper ingots from these wastes. Unlike conventional powder metallurgy techniques, the process employs a low-pressure (7 bar) and short-term (5 minute) sintering step without prior surface cleaning. Initially, the chips undergo pre-compression at 200°C, followed by heat treatment at 1035°C, and subsequently a secondary pressing to yield copper ingots. X-ray diffraction analysis predominantly identified the face-centered cubic copper phase, while energy dispersive spectroscopy indicated only trace amounts of oxygen and iron. The abbreviated sintering duration successfully preserved over 97% of the metallic copper phase and minimized oxide formation. Scanning electron microscopy confirmed a homogeneous microstructure, with crystallite sizes and morphology optimized based on the sintering conditions. This approach offers substantial advantages in terms of energy savings, production efficiency, and environmental sustainability.