Abstract: This study explores the sustainable production and performance characteristics of 6060 aluminum alloys enhanced with increased copper (Cu) and zinc (Zn) concentrations, emphasizing the use of recycled aluminum in the casting process. The proportion of recycled content was quantified, and the associated reduction in CO₂ emissions was estimated relative to conventional primary aluminum production. Three alloy variants were examined: a balanced primary aluminum alloy with minimal Cu (0.01%) and Zn (0.02%) content, and two recycled compositions containing 60% and 80% remelted scrap, respectively, with increased Cu (0.017% and 0.028%) and Zn (0.034% and 0.06%) levels. Grain size measurements of the extrudates were conducted, and Corrosion analysis in parallel with acetic salt spray tests were conducted to assess the impact of these compositional changes. The findings indicate that higher Cu and Zn concentrations do not significantly compromise corrosion resistance. Additionally, real-time imaging during extrusion and subsequent anodize finish on them have been also investigated. The results underscore the feasibility of sustainable alloy design that maintains material performance, supporting a transition toward greener aluminum manufacturing practices.