DESIGNING A PROSTHETIC LEG FROM SCRAP ALUMINIUM BEVARAGE CANS

Abstract

In this research, a prosthetic leg pylon was developed using recycled aluminium cans which were collected from refuse sites, washed and pre-treated with sulphuric acid. They were melted at 1190°C, and alloyed with iron and brass to enhance mechanical properties. Five alloy samples with varying compositions (Al, Fe, brass) were tested for compressive strength, tensile strength, hardness, microstructure, and corrosion resistance. The optimal composition constituted of 96.1 wt% Al, 1.9 wt% Fe, and 2 wt% brass, demonstrating superior hardness and tensile strength properties. High iron content (7.6 wt%) led to porosity, reducing strength and hardness, while lower iron content (0 wt%) caused hot tears. Microstructure analysis revealed copper-rich intermetallic phases and β-phase iron-rich needle-shaped intermetallic phases, contributing to improved mechanical properties. The recycled aluminium pylon exhibited competitive compressive strength, tensile strength, and hardness to the standard market pylon. This innovative approach utilizes waste materials to create affordable prosthetic limbs, promoting sustainability and accessibility. The findings demonstrate the potential for recycled aluminium alloys in prosthetic applications, offering a cost-effective solution for above the knee amputees in need.