Multidisciplinary treatment of molten aluminum combined burn:An unusual case report

Molten aluminum is among the most common causes of burns in the metal industry.However,only few reports are available on molten aluminum injuries.Herein,we report an unusual case of molten aluminum burn.The patient had burns not only on the body surface but also in the respiratory tract and esophagus,adding to the difficulty of treatment.Multidisciplinary consultation and cooperation led to the development of a treatment plan for the patient,which included tracheotomy,respiratory management,endoscopic therapy,infection control,and psychological support.To our knowledge,this is the first report of molten aluminum-induced burns involving the face,neck,respiratory tract,esophagus,and eyes.We also describe our experience with multidisciplinary treatment for the management of molten aluminum burns.

Review on corrosion-wear resistance performance of materials in molten aluminum and its alloys

The failure caused by the corrosion-wear of molten aluminum and its alloys is one of the main problems in aluminum industry. In this work, the resistance behavior of various materials, including Fe-based alloys, ceramics and corresponding high apparatus of corrosion-wear in molten aluminum and its alloys, were reviewed. The synergistic effect of corrosion and wear was discussed based on corrosion and wear mechanics. The effects of dynamic agitation due to rotating of friction pairs, physical property of liquid metal and size of grain etc., on the corrosion-wear resistance performance were investigated. In addition, the characteristics of corrosion-wear resistance performance of materials in molten aluminum and its alloy were summarized. According to our recent progress referred to kinds of materials, especially a TiA13/Ti3A1C2/A1203 composite, the ceramics/metal composites with a co-continuous structure will be of great advantage in the field of corrosion-wear environment of molten aluminum and its alloys.

Corrosion resistance of 91W-6Ni-3Fe refractory metal,TiAl compound and iron based alloys in molten aluminum

The corrosion behaviors of 91W-6Ni-3Fe （91W） refractory alloy, TiAl intermetallic compound and two types of iron based alloys （QT700 and H13 tool steel） in a liquid aluminum were investigated. Corrosion experiments or static immersion-tests were carried out in pure molten aluminum at 750 ℃. The surface micro-topographies, corrosion interfaces and phase compositions of the immersed samples were investigated by 3D optical microscopy, SEM, EDS and XRD. The results show that 91W exhibits the best corrosion resistance, followed by QT700, H13 and TiAl alloy, consequently. The corrosion mass loss of the four metallic materials adheres to parabolic criterion, and the corrosion rate trends to be stable after initial acceleration. The diffusion-reaction mechanism is proposed for the dissolution of materials in molten aluminum, and the diffusion process is the rate-determining step during the dissolution of 91W in molten aluminum, while the low activation energy for the reaction between TiAl-（TiAl3）-Al couple results in poor corrosion resistance of TiAl alloy in molten aluminum.

Properties of a reaction-bonded β-SiAlON ceramic doped with an FeMo alloy for application to molten aluminum environments

An FeMo-alloy-doped β-SiA1ON （FeMo/β-SiA1ON） composite was fabricated via a reaction-bonding method using raw materials of Si, Al2O3, A1N, FeMo, and Sm2O3. The effects of FeMo on the microstructure and mechanical properties of the composite were investi- gated. Some properties of the composite, including its bending strength at 700℃ and after oxidization at 700℃ for 24 h in air, thermal shock resistance and corrosion resistance to molten aluminum, were also evaluated. The results show that the density, toughness, bending strength, and thermal shock resistance of the composite are obviously improved with the addition of an FeMo alloy. In addition, other properties of the composite such as its high-temperature strength and oxidized strength are also improved by the addition of FeMo alloy, and its corrosion re- sistance to molten aluminum is maintained. These findings indicate that the developed FeMo/β-SiA1ON composite exhibits strong potential for application to molten aluminum environments.

A new dynamic method for measuring hydrogen partial pressure in molten aluminum alloy

Hydrogen partial pressure is an important parameter to calculate hydrogen concentration levels in molten aluminum alloy. A new dynamic method for measuring hydrogen partial pressure in molten aluminum alloy is studied. Dynamic and rapid measurement is realized through changing the volume of the vacuum chamber and calculating the pressure difference ΔP between the theoretical and measured pressures in the vacuum chamber. Positive ΔP indicates hydrogen transmits from melt to vacuum chamber and negative ΔP means the reverse. When ΔP is equal to zero, hydrogen transmitted from both sides reached a state of dynamical equilibrium and the pressure in the vacuum chamber is equal to the hydrogen partial pressure in the molten aluminum alloy. Compared with other existing measuring methods, the new method can significantly shorten the testing time and reduce measuring cost.

Microstructure and Corrosion Resistance of CrN and CrN/TiN Coated Heat-Resistant Steels in Molten Aluminum Alloy

The components of the equipment for processing the Al melts into the molded parts can be markedly corroded by the molten Al. In this study, a 4 μm CrN coating or CrN/TiN multilayer coating for providing the physical and chemical barriers between the molten reactive Al and the steel substrate were deposited by Cathodic Arc Evaporation onto 10 mm-thick heat-resistant steel plates. The dipping tests were conducted in a 700℃ A356 melt for 1 to 21 h at intervals of 3 h. The damage of the coated steel was eva...

INTERACTION OF OXIDE FILM WITH MOLTEN FLUX DURING ALUMINUM BRAZING

The interaction of oxide film with molten flux during aluminum brazing has been studied by means of X-ray powder diffraction. The following conclusions have been deduced: The swell- ing of aluminum oxide film is caused by Li^+ inserting into the vacancies of octahedral or tetrahedral structure of 0 atom skeleton in у-Al_2O_3 . The strength of oxide film decreases as the crytallinity increases by the treating of flux containing LiF.

Electrodeposition of aluminum on needle cathode using AlCl3/urea molten salts at low-temperature and its application to hydrogen generation

The electrodeposition of aluminum(Al)was studied using two electrolyte solutions,such as anhydrous AlCl3-urea and hydrated AlCl3·6 H2 O-urea.A systematic examination using cell voltages 1.0–2.0 V was carried out at temperatures((50–100)±2)°C.A needle-shaped cathode was employed for the deposition of aluminum.A dendrite and particulate microstructure of Al were observed on the needle-shaped cathode.An improved condition for the manufacturing of small sizes and high purity of aluminum deposits was obtained.Pure Al with a current efficiency(yield)of 84%–99%was obtained from those of non-aqueous electrolytes and only of 8.6%–9.3%from those of hydrated electrolytes.The electrical conductivities of electrolytes remained considerable at((50–100)±2)°C.The improved aluminum powders were used for the reaction with water.The aluminum reacts with water at room temperature,producing pure H2 with 100%yield.The electrodeposited aluminum metal can be used as an excellent energy carrier.

Nitrogen Injection in Molten Aluminum in a Tank Degasser

The injection of nitrogen in molten aluminum through a static impeller in a tank degassing unit is studied. Using basic principles of fluid mechanics, it is analyzed the influence of the nozzle diameter on the bubble diameter and the mean residence time of the bubbles in the molten aluminum. By means of transient isothermal 2D Computational Fluid Dynamics (CFD) simulations, the influence of the nitrogen volumetric flow rate on the phase distributions and the tank degasser dynamics is studied. Finally, an adiabatic CFD simulation is carried out in order to elucidate the changes in the molten aluminum temperature due to the injection of nitrogen at ambient temperature. This simulation shows that molten aluminum does not suffer drastic temperature reductions given that, in spite?that?the nitrogen is fed at ambient temperature, the mass of nitrogen is relatively small compared with the mass of aluminum.

Mechanism of removing inclusions from molten aluminum by stirring active molten flux

Removal of inclusions from industrial pure molten aluminum(A01) by stirring active molten flux was studied. Wettability of nonmetallic inclusions in the molten aluminum was worse than that in active molten flux. According to the surface renewal model, the inclusions were easily transferred into molten active flux from fine aluminum droplets and then reacted chemically when molten aluminum was dispersed into fine aluminum droplets in stirring active molten flux. Tensile tests show that tensile strength of purified tensile sample(as-cast) increases by 8.59%. SEM photographs show that the fracture cracks of purified tensile sample are homogeneous, and the dimples are small and homogeneous. From metallographs and statistic results of Leco analysis software, it is found that the quantities and sizes of the inclusions in purified sample are obviously fewer and smaller than in unpurified tensile sample(as-cast).

A New Ceramic Substrate Glaze with High Resistance to Molten Aluminum

Corrosion resistance of ceramic substrate glazes to molten aluminum was studied in this paper. The glazes can spread slightly in aluminum alloy according to SEM examination of solidified interface between the glazes and aluminum alloy. The components of B2O3-P2O5 glazes were not detected with electron probe at the side of aluminum alloy near the interface, but the components of boron-free glaze were detected. It is shown that borophosphate glazes can resist the corrosion of molten aluminum.

Removal of inclusions from molten aluminum with actively coated ceramic filters

Molten aluminum (A001) was filtered by using ceramic foam filters coated with active enamel. Tensile test shows that the elongation of filtered sample is increased by 15.5%, but the tensile strength of the sample is almost the same as that of unfiltered one. The fracture cracks and dimples of filtered sample are fine and homogeneous according to SEM examination. In addition, metallographic observation shows that the filtered sample has very few inclusions of approximately 8 μm in diameter, but the unfiltered sample has some inclusions of approximately 60 μm in length and 20 μm in width. However, it is suggested that the active enamel coat can effectively capture the inclusions and dissolve them during filtering molten aluminum.

Determining the Boundary of Molten Electrolyte and Aluminum in Electrolytic Cells by Detecting Their Vertical Distribution of Potential

Aluminum production is a high energy consumption process so that maintaining fundamental compositions in balance and optimal conditions are essential.The molten electrolyte and melted aluminum are primary materials and their boundary needs to be monitored from time to time.An automatic measurement technic is presented in the paper to substitute for the traditional manual measurement work that is dull,poor efficiency and dangerous for operators.The boundary forming mechanism is analyzed,the vertical profile of electric potential is simulated,an automatic instrument is developed to sense the potential distribution,and a strategy is provided to identify the boundary according to the potential curves.Finally,some practical results are compared with manual measurements,which shows good consistency.

Current efficiency of recycling aluminum from aluminum scraps by electrolysis

Extracting aluminum from aluminum alloys in AlCl3-NaCl molten salts was investigated. Al coating was deposited on the copper cathode by the method of direct current deposition using aluminum alloys as anode. The purity of the deposited aluminum is about 99.7% with the energy consumption of 3-9 kW＆#183;h per kg Al, and the current efficiency is 44%-64% when the deposition process is carried out under 100 mA/cm2 for 4 h at 170 ＆#176;C. The effects of experimental parameters, such as molar ratio of AlCl3 to NaCl, cathodic current density and electrolysis time, on the current efficiency were studied. The molar ratio of AlCl3 to NaCl has little effect on the current efficiency, and the increase of deposition temperature is beneficial to the increase of current efficiency. However, the increase of current density or electrolysis time results in the decrease of current efficiency. The decrease of current efficiency is mainly related to the formation of dendritic or powder deposit of aluminum which is easy to fall into the electrolyte.

Electrochemical behavior of Li incorporation in Al in LiTFSI/KTf molten salt electrolyte

The electrochemical behavior of lithium incorporated in aluminum electrode in LiTFSI/KTf （lithium bis （trifluoromethylsulfonyl） amide/CF3SO3K） molten salt electrolyte was studied by a variety of electrochemical techniques including cyclic voltammetry, chronopotentiometry and chronoamperometry. The reduction reaction is found involving a nucleation process on the aluminum electrode. The results of chronopotentiometry indicate that the process of lithium incorporation in aluminum is smooth and uniform. The galvanostatic cycle experiments show that the coulombic efficiency is very low in the first cycle, which is mainly due to the ＂retention capacity＂ of Li-Al alloys. This characteristic is testified by the results of XRD and SEM. The results of chronoamperometry indicate that the incorporation of lithium into aluminum for the formation of a-phase Li-Al alloy is limited by its diffusion rate, with a measured diffusion coefficient of 1.8× 10^-10 cm2/s.

Nanosheet-stacked flake graphite for high-performance Al storage in inorganic molten AlCl_(3)-NaCl salt

Aluminum storage systems with graphite cathode have been greatly promoting the development of state-of-the-art rechargeable aluminum batteries over the last five years;this is due to the ultra-stable cycling,high capacity,and good safety of the systems.This study discussed the change of electrochemical behaviors caused by the structural difference between flake graphite and expandable graphite,the effects of temperature on the electrochemical performance of graphite in low-cost AlCl_(3)-NaCl inorganic molten salt,and the reaction mechanisms of aluminum complex ions in both graphite materials by scanning electron microscopy,X-ray diffraction,Raman spectroscopy,cyclic voltammetry,and galvanostatic charge-discharge measurements.It was found that flake graphite stacked with noticeably small and thin graphene nanosheets exhibited high capacity and fairly good rate capability.The battery could achieve a high capacity of^219 mA·h·g^(-1) over 1200 cycles at a high current density of 5 A·g^(-1),with Coulombic efficiency of 94.1%.Moreover,the reaction mechanisms are clarified:For the flake graphite with small and thin graphene nanosheets and high mesopore structures,the reaction mechanism consisted of not only the intercalation of AlCl4^-anions between graphene layers but also the adsorption of Al Cl4^-anions within mesopores;however,for the well-stacked and highly parallel layered large-size expandable graphite,the reaction mechanism mainly involved the intercalation of AlCl4^-anions.

Physical and Electrochemical Properties of Acid 1-Methyl-3-Ethylimidazolium Chloride/AlCl_3/LiAlCl_4 Molten Salt

An acid molten salt was formed by means of mixing 1 -methyl- 3 -ethylimidazolium chloride with AlCl3 and LiAlCl4 at ambient temperature. The solubility of LiAlCl4 in the acid molten salt was measured. Variations of specific conductivity, density and kinetic viscosity of molten salt with mole ratio o f MeEtlmCl/A1lCl3/LiAlCl4 were observed. A solubility maximum of LiAlCl4 with 5 4% in molar fraction was shown at a mole ratio of AlCl43/MeEtlmCl = 1 .2. An increase in density and viscosity, and a decrease in specific conductivity were found with increasing the concentrations of LiAlCl4 and AlCl3. The dependence of specific conductivity of this acid molten salt upon temperature was found to display Vogel-Tammanm-Fucher behavior. However, Arrhenius behavior was observed at two special mole ratios of MeEtImCl/AlCl3/LiAlCl4 = 1:1.5:0.05 and 1. 1.5:0. 10. The conductivity equations of this molten salt at various compositions were constructed. The ion interaction in the acid molten salt was studied using 7Li and 27Al nuclear magnetic resonance spectroscopic methods. The effect of concentrations of LiAlCl4 and AlCl3 on the ion interaction was also discussed.

熔盐电解质体系及在制备铝合金中的研究进展

铝合金具有抗腐蚀、易于加工、强度高、密度小等优点,在各行各业中都有着大量的应用。采用熔盐电解法制备铝合金具有生产工艺简单、效率高、生产成本低、生产周期短等特点,近些年来得到广泛关注,其中熔盐体系的选择成为主要的研究热点。本文以温度划分熔盐体系为高温熔盐和离子液体,综述了这2种熔盐体系的优点、分类以及一些反应机理,并从这2类熔盐体系出发,分别介绍了一些铝合金的制备工艺以及相关的技术创新。最后,分别阐述了高温熔盐和离子液体所存在的优缺点,并对其未来发展趋势进行了展望。

铝电解惰性阳极在熔融电解质中腐蚀过程的研究进展

惰性阳极是原铝生产保持低碳化的重要研究方向,近些年,惰性阳极材料的研究取得长足进展。通过对惰性阳极材料进行分类,综述了不同种类(合金阳极、氧化物陶瓷阳极和金属陶瓷阳极)的惰性阳极在熔盐电解质中可能发生的腐蚀反应,主要探究发生的化学腐蚀和电化学腐蚀,以及腐蚀后可能对阳极的影响。明晰增加阳极耐腐蚀性的方法,或者通过抑制腐蚀反应的进行,来降低惰性阳极在冰晶石熔盐中的腐蚀速率,从而促进惰性阳极在铝电解行业中的可行性发展。

锌离子路易斯酸熔盐体系从粗四氯化锆中除铝机制研究

为了降低传统沸腾氯化法制备的粗ZrCl_(4)中Al杂质含量,达到高品质锆前驱体的精度要求,开发了适合粗ZrCl_(4)高效除Al的锌离子路易斯酸熔盐体系,使其中的杂质Al含量由0.16%降低至0.001%。同时,根据路易斯酸熔盐体系与粗ZrCl_(4)中Al^(3+)的反应,通过基于密度泛函理论的CASTEP模块对Al^(3+)在复盐中的结合量和结合能进行分析,进而确立粗ZrCl_(4)除Al机制。Al^(3+)结合量的降低和结合能的升高有助于Al^(3+)从复盐中脱离,从而降低粗ZrCl_(4)中Al含量。通过实验与理论计算验证了锌离子路易斯酸熔盐体系能够从粗ZrCl_(4)中有效除Al。本研究可为制备高品质核级锆提供新思路和理论基础。