The mechanism of Fe-rich intermetallic compound formation and growth on inoculants revealed by electron backscattered diffraction and X-ray imaging

•The paper concerns a new compositional design approach to make aluminium alloys more recyclable.•As a possible route to gaining greater control of Fe-rich intermetallic compound formation in recycled Al alloys, the formation and growth of Al13Fe4 intermetallics on of Al3Ti inoculants are studied systematically in high Fe-containing Al alloys, combining electron backscattered diffraction and X-ray imaging.•Crystallographic orientation relationships between Al13Fe4 and Al3Ti are analysed comprehensively, and the formation and growth dynamics of Al13Fe4 on Al3Ti is also unveiled.•A strong link is revealed between the formation of Al13Fe4 on Al3Ti and a twinning-related pseudo-symmetry of Al13Fe4.•A potential strategy to refine both Fe-rich intermetallics and α-Al in recycled alloys with elevated Fe concentration is proposed for more Fe-tolerant alloy recycling.