A Method of Producing Al–REE Master Alloys Using Exchange Reduction Reaction

Modern aerospace engineering relies on Al-based alloys with enhanced high-temperature strength properties and oxidation resistance. These requirements can be fulfilled by modifying alloys’ structure employing rare earths metal doping. Direct addition of metallic rare earths to aluminium is complicated due to high chemical activity of molten rare-earth metals and significant vapor pressure of aluminium at elevated temperatures. To overcome these drawbacks, lanthanide-containing master alloys with relatively low REE content can be employed instead of pure scandium. Currently there are three methods for preparing aluminium-based alloys containing rare earths, i.e. direct fusing, molten salt electrolysis and exchange or metallothermic reduction reactions. In the last case, Al–Gd and Al–Sc master alloy can be prepared by aluminothermic reduction of GdF 3 or ScF 3 in a molten binary NaF–KCl salt mixture at 800–1050 °С. In the present work we suggest the modification of the above mentioned method for aluminium–cerium and aluminium–neodymium master alloy production with a lanthanide concentration of 1 to 7 wt. %. Based on thermodynamic calculations we proposed that the high-temperature exchange reaction between metallic aluminum and corresponding fluoride containing salt electrolyte should be carried out at temperatures from 740 to 780 ° C to provide the higher recovery of REE. The influence of the time of the exchange reaction and «aluminium–salt» ratio on the process to obtain ligatures of various compositions is analyzed. The yield higher than 85 % is achieved. The microstructure of the alloys represents a metal matrix of aluminum in which intermetallic compounds of Ln 3 Al 11 compositions are distributed In the case of an exchange reaction between aluminum and cerium fluoride, the formation of a new phase, presumably related to the Al 4 Ce intermetallic compound, is found.