Abstract: Disclosed methods relate to producing an aluminum-scandium (Al—Sc) alloy. A method can include providing an electrolyte bath comprising a first portion of at least one of ScF3 or AlF3 and a first portion of at least one of LiF, NaF, or KF; providing a cathode in electrical contact with the electrolyte bath; providing an anode in electrical contact with the electrolyte bath; adding a first portion of SC2O3 into the electrolyte bath; reacting an aluminum ion with the cathode; applying an electric current to the cathode, thereby reacting a scandium ion with the cathode to produce the Al—Sc alloy.

Abstract: Disclosed methods relate to producing an aluminum-scandium (Al—Sc) alloy. A method can include providing an electrolyte bath comprising a first portion of at least one of ScF3 or AlF3 and a first portion of at least one of LiF, NaF, or KF; providing a cathode in electrical contact with the electrolyte bath; providing an anode in electrical contact with the electrolyte bath; adding a first portion of SC2O3 into the electrolyte bath; reacting an aluminum ion with the cathode; applying an electric current to the cathode, thereby reacting a scandium ion with the cathode to produce the Al—Sc alloy.

Abstract: A method for qualifying an automated process for inspecting and sorting particles through the production and use of seed particles is disclosed. In one embodiment, seed particles are produced by forming a conformal surface layer on a plurality of particles, thereby imparting them with at least one property whose value or range of values is the same as or about the same as a value or range of values of a corresponding property of undesirable particles. By introducing a predetermined quantity of seed particles, their detection and removal by the automated sorting system can be used to periodically calibrate and qualify the sorting system without interrupting the manufacturing operations or introducing actual undesirable particles into the process stream. The production and use of seed particles to qualify an automated sorting system is particularly well-suited for use with Ti sponge sorting operations.

Abstract: A method for qualifying an automated process for inspecting and sorting particles through the production and use of seed particles is disclosed. In one embodiment, seed particles are produced by forming a conformal surface layer on a plurality of particles, thereby imparting them with at least one property whose value or range of values is the same as or about the same as a value or range of values of a corresponding property of undesirable particles. By introducing a predetermined quantity of seed particles, their detection and removal by the automated sorting system can be used to periodically calibrate and qualify the sorting system without interrupting the manufacturing operations or introducing actual undesirable particles into the process stream. The production and use of seed particles to qualify an automated sorting system is particularly well-suited for use with Ti sponge sorting operations.

Abstract: A composition of matter suitable for use as a protective flux in the production of magnesium metal and magnesium-containing alloys is disclosed. The composition comprises 70 to 80 percent by weight KCl, and 20 to 30 percent by weight MgCl.sub.2 and up to 0.5 percent by weight CaF.sub.2.

Abstract: A process based on molten salt electrolysis for producing pure rare earth metals is disclosed. This process is the direct electrolytic deposition of a rare earth metal such as neodymium, from a molten salt cell containing a mixture of electrolytes and a salt of neodymium, onto a liquid magnesium cathode forming an intermediate alloy. The intermediate alloy is distilled to isolate the neodymium metal. Also disclosed is a process for producing a pure neodymium/iron alloy wherein pure iron is added to the intermediate neodymium/magnesium alloy during the distillation step.

Abstract: A process for producing a magnesium-reactive metal alloy, for example a calcium-magnesium alloy, by electrodepositing the reactive metal from a molten salt bath containing a chloride of said reactive metal directly into a molten pool of magnesium.

Abstract: In a metallothermic process for reducing rare earth metal salts to produce pure rare earth metals and metal alloys, e.g. neodymium or neodymium/iron alloy for use in manufacturing neodymium/boron/iron permanent magnets, including adding pure metallic iron, such as iron flake, to a mixture of metal salt, such as neodymium chloride, and a reducing metal source, such as calcium/magnesium alloy, heating in a crucible in a preheated high temperature furnace with stirring to a temperature of 900 degrees C. under a flow of argon, separating the metal from the salt formed, and purifying the metal via distillation.