Dynamic electromagnetic separation of iron-rich phase inclusions from Al alloy

Electromagnetic separation of the iron-rich phase inclusions from Al alloy was investigated. The influencing parameters including magnetic induction density, the section shape of the separating channel and the length of influential loop of the metal melt on the separation efficiency of iron-rich phase inclusions were studied. The results show that when the proper magnetic induction density (B=0.3T) is applied, rectangle separating channel is used, and the influential loop of the metal melt is long, high separating efficiency of the iron-rich phase inclusions can be obtained.

The microstructure characteristics and fracture behavior of the polyhedral primary iron-rich phase and plate-shaped eutectic iron-rich phase in a high-pressure die-cast AlSi10MnMg alloy

The characterization of multiple iron-rich phases in high-pressure die-cast AlSi10MnMg alloy was studied.Attention was focused on the formation and fracture behavior of the primary iron-rich phase((P-IMC)_(I))formed in the shot sleeve and plate-shaped eutectic iron-rich phase in high-pressure die cast(HPDC)AlSi10MnMg alloy.Results show that multiple types of iron-rich phases with various morphologies,in-cluding primary iron-rich phases(polyhedral(P-IMC)_(I) and(P-IMC)_(II))and eutectic iron-rich phases(plate-shaped,net shape,and fish-bone shape),were found in HPDC AlSi10MnMg.Coarse(P-IMC)_(I) formed in the shot sleeve were distributed in the interface between primaryα-Al and binary Al-Si eutectic.Small size(P-IMC)_(II) and various eutectic iron-rich phases formed in the die cavity and they were distributed in Al-Si binary eutectic.The primary iron-rich phases belonged to a simple cubic crystal structure with a lattice constant a=1.265 nm and they exhibited a lateral growth characteristic with a termination of{110}surface.βphase was surrounded byδphase and they coexisted in a plate-shaped iron-rich phase.High-density stacking fault inβphase andδ/βinterface provided an excellent nucleation site forδphase.From mechanical behavior,the stress concentration caused by eutectic iron-rich phases was far less than(P-IMC)_(I) and it would not cause crack initiation along the eutectic cluster boundary.In addition,(P-IMC)_(I) showed the worst deformation coordination with primaryα-Al while the plate-shaped eutectic iron-rich phase exhibited similar deformation characteristics with silicon particles.

Segregation Behavior and Evolution Mechanism of Iron-Rich Phases in Molten Magnesium Alloys

A new method has been proposed to prepare Mg-A1-Si master alloys by utilizing scrap AI-Si-Fe alloys with higher Fe levels, which aims to segregate Fe from AI-Si-Fe alloys by Mg melt. The segregation be- haviors, microstructure morphology and evolution mechanism of iron-rich phases in Mg-A1-Si alloy melts were studied, after AI-14Si-4Fe （wt%） alloys were added and dissolved completely. In the Mg-A1-Si alloys, iron has very little solubility and tends to combine with other elements to form intermetallic phases, which grow into a deposition layer due to the higher density. During the cooling and solidifying process of Mg-A1-Si melts, the needle-like AlsSiFe phase in AI-14Si-4Fe alloy evolved into blocky AI5Fe2 and Al0.7Fe3Si0.3 phases. Besides, the Fe levels of the Mg-AI-Si master alloys were reduced to 0.017 wt% from nominal content of 0.164 wt%. Based on the above results, this work carried out a semi-quantitative phase- compositions analysis for the deposition layer by relative intensity ratio （RIR） method, and evolution mechanism of the iron-rich phases had also been discussed. This study has paved a new way to regen- erate the scrap AI-Si-Fe alloys, which has a great significance of promoting the recycling of aluminum resources.

Effect of melt holding on morphological evolution and sedimentation behavior of iron-rich intermetallic phases in Al-Si-Fe-Mn-Mg alloy

The effect of the melt holding temperature on the morphological evolution and sedimentation behavior of iron-rich intermetallics in Al-7.0 Si-1.0 Fe-1.2 Mn-0.25 Mg alloy was investigated using an optical microscope,scanning electron microscope and differential thermal analyzer.The results show that as the holding temperature decreases,the morphologies of the primary iron-rich phase in matrix change from star-like to polygonal,and the number of the primary phases gradually decreases and disappears at 615°C.Finally,the Chinese script phases with small size,high compact and uniform distribution are obtained.In contrast,the primary iron-rich phases in slag transform into a coarser polygonal shape with lower roundness,and some of them have hollow structures.Furthermore,the area fraction of intermetallics and Fe content in the matrix decrease gradually due to the formation and growth of sludge and subsequent natural sedimentation during melt holding.With the decrease of holding temperature,the main factors hindering the settlement of the primary phases are morphology,size,and density in turn.

Phase Composition Analysis of TiN-AI_2O_3Synthesized from Aluminum-containing Dross and Rutile by Aluminothermic Reductionnitridation Method

TiN- Al2O3 composite powder was prepared by aluminothermic reduction- nitridation method with starting materials of aluminum-containing dross and rutile,and metallic aluminum in the aluminum-containing dross as reducer. The influences of synthesis temperature（600-1 400 ℃） and aluminum-containing dross addition（20% lower than theoretical value,theoretical value,20% higher than theoretical value,and 50% higher than theoretical value） on phase compositions and microstructure of the composites were investigated,and the reaction mechanism was analyzed. The results show that（1） TiN- Al2O3 composite powder can be synthesized under the experimental conditions; the main phases are TiN,α-Al2O3,a little bytownite,and MgAl2O4;（2）enhancing synthesis temperature or increasing aluminumcontaining dross addition favors the reaction of aluminothermic reduction- nitridation;（3） in the synthesized products,α-Al2O3 is platy or columnar; TiN is sub-micron granular,which reinforces and toughens the composite.

Research of Microstructure,Phase,and Mechanical Properties of Aluminum-Dross-Based Porous Ceramics

In this study,the effect of sintering temperature and the addition of kaolin,a sintering agent,on the microscopic,phase,and mechanical properties of ceramics were investigated using secondary aluminum dross(SAD)as the main component in the manufacturing of ceramics.The basic phases of the ceramics were Al_(2)O_(3),MgAl_(2)O_(4),NaAl_(11)O_(17),and SiO_(2)without the addition of kaolin.The diffraction peaks of MgAl_(2)O_(4),NaAl_(11)O_(17),and SiO_(2)kept decreasing while those of Al_(2)O_(3)kept increasing with an increase in temperature.In addition,the increase in temperature promoted the growth of the grains.The grains were uniform in size and regular in distribution,with a shrinkage of 2.2%,porosity of 72.5%,bulk density of 1.076 g/cm^(3),and compressive strength of 1.12 MPa.When the sintering temperature was 1450°C,the basic phases of the ceramic after the addition of kaolin were Al_(2)O_(3),MgAl_(2)O_(4),NaAl_(11)O_(17),and SiO_(2).With the increase of kaolin,the diffraction peaks of NaAl_(11)O_(17)and SiO_(2)decreased until they disappeared,while the diffraction peaks of Al_(2)O_(3)increased significantly.When kaolin was added at 30 wt.%,the ceramics obtained had shrinkage of 18%,a porosity of 47.26%,a bulk density of 1.965 g/cm^(3),and compressive strength of 31.9 MPa.Cracks existed inside the ceramics without the addition of kaolin,while the addition of kaolin significantly changed this defect.It is shown that SAD can obtain porous ceramics with good properties at a sintering temperature of 1450°C and a kaolin addition of 30 wt.%.

Synergistic effect of gradient Zn content and multiscale particles on the mechanical properties of Al-Zn-Mg-Cu alloys with coupling distribution of coarse-fine grains

This study investigated the influence of graded Zn content on the evolution of precipitated and iron-rich phases and grain struc-ture of the alloys,designed and developed the Al–8.0Zn–1.5Mg–1.5Cu–0.2Fe(wt%)alloy with high strength and formability.With the increase of Zn content,forming the coupling distribution of multiscale precipitates and iron-rich phases with a reasonable matching ratio and dispersion distribution characteristics is easy.This phenomenon induces the formation of cell-like structures with alternate distribu-tion of coarse and fine grains,and the average plasticity–strain ratio(characterizing the formability)of the pre-aged alloy with a high strength is up to 0.708.Results reveal the evolution and influence mechanisms of multiscale second-phase particles and the corresponding high formability mechanism of the alloys.The developed coupling control process exhibits considerable potential,revealing remarkable improvements in the room temperature formability of high-strength Al–Zn–Mg–Cu alloys.

Mn元素对热浸镀Al-10Si-2Fe合金镀层显微组织的影响

在高强钢热浸镀铝硅合金中,通常会有一定量Mn溶解到镀液中,对镀层凝固组织产生影响。本文研究了热浸镀用Al-10Si-2Fe合金中Mn元素对凝固组织及富铁相的影响规律。结果显示,随着Mn含量的增加,铝硅合金中富铁相形貌转变过程如下:针状→汉字状→星状→多边形。借助Pandat软件在热力学层面解释了Mn添加后铝硅合金中β-Al_9Fe_2Si_2相向α-Al_8(Fe,Mn)_2Si相转变的原因。此外,给出了添加Mn后的渣量计算结果,认为铝硅熔液中最佳Mn含量(质量分数)应为0.8%～1.0%。

热浸镀55%Al-Zn镀液中底渣的分析与计算

检测了热浸镀55%Al-Zn镀液的成分和底渣中物相组成,并根据Al-Zn-Si-Fe热力学相图分析了温度对底渣的影响。XRD结果显示,底渣中主要渣相为FeAl3相,另外还含有少量的Al11V;SEM和EDS的结果也证明底渣中主要渣相为FeAl3,并且检测到少量Al-Zn-V-Ce四元金属间化合物。热力学相图分析浸镀温度对Fe在镀液中饱和溶解度的影响表明,随着温度升高,Fe的溶解度也随之增加。当镀液中Fe含量超过该温度下的饱和溶解度时,就以FeAl3的形式从镀液中析出成为底渣。

温度和铝含量对锌铝池中锌渣形成的影响

采用扫描电镜(SEM)和X射线能谱仪(EDS)分别对480~620℃范围内的Zn-22.3%Al、530~620℃范围内的Zn-30%Al和620℃下的Zn-55%Al(Al含量均为质量分数)镀锌铝池中锌渣的组成相及其形成规律进行系统分析与研究。结果表明,Zn-22.3%Al锌铝池在480℃和500℃下形成与由τ5和τ6相组成的面渣,在520℃形成的面渣为τ5相;Zn-30%Al锌铝池在530℃和550℃下也生成由τ5和τ6相组成的面渣,但570℃下面渣仅为τ5相。Zn-22.3%Al锌铝池由于密度低,在620℃时仅生成面渣(τ2+Fe Al3);Zn-30%Al锌铝池在620℃时除了生成面渣(τ5+Fe Al3)外,中间层还生成τ5和τ6相锌渣;Zn-55%Al锌铝池在620℃下除了形成底渣τ5相以外,中间层还生成τ6相锌渣。

金红石和铝灰铝热还原氮化合成TiN-Al_2O_3的物相研究

以金红石和铝灰为原料,以铝灰中的金属铝为还原剂,采用铝热还原氮化法合成TiN-Al2O3复合粉体,研究了合成温度(600～1 400℃)和铝灰配入量(比理论量少20%、理论量、比理论量多20%、比理论量多50%)对合成产物的物相组成和显微结构的影响,并分析了反应机制。结果表明:1)以铝灰和金红石为原料,以铝灰中的金属铝为还原剂,通过铝热还原氮化法可制得TiN-Al2O3复合粉体,其主要物相为TiN、α-Al2O3以及少量倍长石和MgAl2O4。2)提高合成温度或增加铝灰配入量均有利于铝热还原氮化反应的进行。3)合成产物中α-Al2O3呈板片状和柱状;TiN主要呈粒状,粒径为亚微米级,能在TiN-Al2O3复相材料中起补强增韧的作用。

二次铝灰中氟氮物相的光谱分析

二次铝灰是电解铝、铝加工、铝回收行业产生的危险废物,不同生产过程排放的二次铝灰具有矿相复杂、化学组成波动大的特点,造成现有处置技术对各类二次铝灰的处理效果差异较大,资源化利用率低。通过明确典型铝合金生产过程排放二次铝灰中含氮、含氟物相等毒害组分的赋存形态及分布规律,判断氟氮物相形成途径,有利于开发高适性的二次铝灰无害化技术,实现二次铝灰中毒害组分和有价组分的高效分离,有效解决其资源化利用难题。结合化学与仪器分析,利用X射线衍射、X射线荧光光谱定量研究了生产过程中不同系列三种铝合金产生的二次铝灰中含氟物相、含氮物相等物相含量,采用X射线光电子能谱、扫描电子显微镜与能谱系统分析氟、氮元素的结合形态和分布特征。结果表明,使用光谱分析方法与化学分析方法对二次铝灰中氮化物、氟化物的定量检测结果基本相符。铝-硅、铝-镁、铝-镁-硅三种系列铝合金生产过程得到的二次铝灰中含氮物相含量为4.30%~5.48%,含氮物相均主要以AlN形式存在,由生产过程中铝熔体与氮气反应生成物进入二次铝灰。AlN主要分布在体相中,颗粒形貌呈球端条状或棱块状,以游离单独颗粒或与含铝物相连生的形式存在;二次铝灰中含氟物相含量为1.04%~2.29%,铝-硅系列合金生产过程得到的二次铝灰中含氟物相以NaF,CaF_(2),MgF_(2)和Na_(3)AlF_(6)形式存在,在铝-镁、铝-镁-硅合金生产得到的二次铝灰中含氟物相以CaF_(2),MgF_(2)和KF形式存在;含氟物相均作为添加剂在铝产品生产过程中进入二次铝灰,在二次铝灰生成过程中未发生其他反应生成新相。三种样品中含氟物相在表面富集,形貌呈团絮状或不规则块状,以附着、包覆大颗粒,与其他组分连生、游离单独颗粒的形式存在。本研究可为二次铝灰中氟、氮等毒害杂质的脱除提供理论依据及基础支撑。

从铅浮渣反射炉烟尘提取铟的生产实践

采用二段浸出、萃取、酸洗、反萃、置换、压团,熔铸、电解铸型新工艺,能成功地从铅浮渣反射炉烟尘中提取铟,该工艺简单、技术可靠,具有投资省、铟总回收率高、铟锭产品质量高等特点。

铸铅阳极前加锑作业浮渣的工艺矿物学研究

发现了 Cu_2Sb、Cu_5Sb_2、Cu_3Sb、Cu_4Sb 和 Cu_5Sb,统称为锑铜矿系列相.拟按铜与锑的原子比不同,分别称之为二铜锑矿、五铜二锑矿、三铜锑矿、四铜锑矿和五铜锑矿.它们是熔铅加锑工艺的生成相.加锑作业浮渣含铜14.15%、含锑12.80%,其中95%的铜锑以锑铜矿系列相形式存在;据此计算,加锑前多除1000 kg 铜,可减少锑耗905 kg.因此,在加锑作业前实行强化除铜,能大幅度降低锑耗,甚至有可能实现加锑作业的无浮渣工艺.

Migration Behavior of Impurity Iron in Silicon Melt Under Pulsed Electric Current

The impurity iron in silicon material will seriously affect the photoelectric conversion efficiency of silicon solar cells.However,the traditional silicon purification method has the disadvantages of long cycle,high energy consumption and serious pollution.In this study,an efficient and green pulsed electric current purification technology is proposed.The electromigration effect of iron elements,the current density gradient driving of iron phase,and the gravity of iron phase all affect the migration behavior of iron phase in silicon melt under pulsed electric current.Regardless of the depth of electrode insertion into the silicon melt,the solubility of iron in silicon decreases under the pulsed electric current,which helps to form the iron phase.At the same time,the iron phase tends to sink toward the bottom under the influence of gravity.When the electrode is shallowly inserted,a non-uniform electric field is formed in the silicon melt,and the iron phase is mainly driven by the current density gradient to accelerate sink toward the bottom.When the electrode is fully inserted,an approximately uniform electric field is formed in the silicon melt,and iron elements are preferentially migrated to the cathode by electromigration,forming iron phase sinking at the cathode.The study of impurity iron migration behavior in silicon melt under pulsed electric current provides a new approach for the purification of polycrystalline silicon.

铝灰中有害元素脱除及钙化转相制备铝酸钙

铝灰是铝工业产生的危险固体废弃物,其中含有氯、氮等有害元素和较多的氧化铝,具备危废和资源的双重属性。为了实现铝灰中有害物质的脱除和氧化铝资源的回收利用,基于铝灰化学成分及物相组成分析,开展铝灰高温脱氮除氯及钙化转相制备铝酸钙试验,研究铝灰制备铝酸钙反应过程热力学、配比及温度对产物物相的影响。研究结果表明,在1 300℃下焙烧1 h,铝灰中的有害组分在高温下得以有效脱除,氮和氯元素脱除率分别为98.16%和99.33%;当物料Al_(2)O_(3)和CaO的质量比为0.36~1.79、控制焙烧温度为1 320℃时,可获得以7Al_(2)O_(3)·12CaO为主要物相的低熔点铝酸钙产品,所得到的铝酸钙产品可满足普通型炼钢用预熔型铝酸钙产品质量标准要求。