The direct conversion of aluminum alloy machining chips into finished or semi-finished products through hot extrusion offers a promising solution for enhancing energy efficiency in aluminum recycling and minimizing material loss during remelting. In this process, aluminum chips are compacted into chip-based billets and extruded at elevated temperatures to create chip-based aluminum extrudates. However, extrudates produced with conventional dies often exhibit inferior mechanical properties compared to those made from extruded cast billets. Key factors influencing the bonding quality of the chips, and thus the mechanical properties of the extrudates, include shear, pressure, and strain during extrusion. This thesis explores the adaptation of hot extrusion with integrated equal channel angular pressing (iECAP) for processing aluminum alloy machining chips. By incorporating ECAP principles into the extrusion die, additional shear, strain, and pressure are applied to the material. An iECAP die was developed, and the effects of strain and pressure on the chips during hot extrusion were analyzed. The quality of chip bonding and the mechanical properties of extrudates produced with the iECAP die were evaluated against those made with conventional dies, using the mechanical properties of extruded cast billets as a benchmark. Additionally, the impact of heat treatment on these properties and the potential for producing finished parts th
