Abstract: New copper-coated titanium diboride electrodes are disclosed. The copper-coated titanium diboride electrodes may be used in an aluminum electrolysis cell. In one embodiment, a method includes installing the copper-coated titanium diboride electrode in the aluminum electrolysis cell and operating the aluminum electrolysis cell. During start-up, the aluminum electrolysis cell may be preheated and a bath may be formed from a molten electrolyte. Alumina (Al2O3) may in the added to the bath and reduced to aluminum metal. At least some of the copper film of the copper-coated titanium diboride electrode may be replaced by an aluminum film, thereby forming an aluminum-wetted titanium diboride electrode.

Abstract: The present disclosure relates to products, systems, and methods for producing purified liquid metal (e.g., purified aluminum) from a feedstock (e.g., aluminum feedstock) in an electrolytic cell (e.g., purification cell) by purifying the feedstock and moving the purified liquid metal from a first location of the cell to a second location via at least one directing feature. The at least one directing feature may be electrically neutral and may be located proximal the first location. The at least one directing feature may be in fluid communication with the purified liquid metal (e.g., purified aluminum) and the second location.

Abstract: New copper-coated titanium diboride electrodes are disclosed. The copper-coated titanium diboride electrodes may be used in an aluminum electrolysis cell. In one embodiment, a method includes installing the copper-coated titanium diboride electrode in the aluminum electrolysis cell and operating the aluminum electrolysis cell. During start-up, the aluminum electrolysis cell may be preheated and a bath may be formed from a molten electrolyte. Alumina (Al2O3) may in the added to the bath and reduced to aluminum metal. At least some of the copper film of the copper-coated titanium diboride electrode may be replaced by an aluminum film, thereby forming an aluminum-wetted titanium diboride electrode.

Abstract: The application is directed to products and methods related to an aluminum electrolysis cell with a non-carbonaceous substrate with a directing feature. The directing feature can be configured to direct a wettable material in a predetermined direction. The non-carbonaceous substrate can be at least partially covered with solid aluminum metal. The wettable material can be aluminum metal.

Abstract: The present disclosure relates to methods of making electrodes for use in electrolysis cells. The method may include forming a TiB2 feedstock into a predetermined shaped product to realize an appropriate density. The method may also include producing a final shaped product from the predetermined shaped product by exposing the predetermined shaped product to elevated temperature. Due to the exposing step, the final shaped product may have a plurality of pores and may realize one or more properties and/or characteristics.

Abstract: In one embodiment, the disclosed subject matter relates to an electrolytic cell that has: a cell reservoir; a cathode support retained on a bottom of the cell reservoir, wherein the cathode support contacts at least one of: a metal pad and a molten electrolyte bath within the cell reservoir, wherein the cathode support includes: a body having a support bottom, which is configured to be in communication with the bottom of the electrolysis cell; and a support top, opposite the support bottom, having a cathode attachment area configured to retain a at least one cathode plate therein.

Abstract: The application is directed to products and methods related to a TiB2 substrate with a directing feature, wherein the directing feature is configured to direct TiB2 wettable material in a predetermined direction. In some embodiments, the TiB2 substrate is at least partially covered with solid aluminum metal.

Abstract: The application is directed to products and methods related to an aluminum purification cell with a non-carbonaceous substrate with a directing feature. The directing feature can be configured to direct a wettable material in a predetermined direction. The non-carbonaceous substrate can be at least partially covered with solid aluminum metal. The wettable material can be aluminum metal.

Abstract: Systems and methods for making ceramic powders configured with consistent, tailored characteristics and/or properties are provided herein. In some embodiments a system for making ceramic powders, includes: a reactor body having a reaction chamber and configured with a heat source to provide a hot zone along the reaction chamber; a sweep gas inlet configured to direct a sweep gas into the reaction chamber and a sweep gas outlet configured to direct an exhaust gas from the reaction chamber; a plurality of containers, within the reactor body, configured to retain at least one preform, wherein each container is configured to permit the sweep gas to flow therethrough, wherein the preform is configured to permit the sweep gas to flow there through, such that the precursor mixture is reacted in the hot zone to form a ceramic powder product having uniform properties.

Abstract: Systems and methods for making ceramic powders are provided. The method for forming a ceramic powder includes: preparing a precursor mixture, wherein the preparing comprises adding at least one additive to a plurality of reagents, wherein the at least one additive includes at least one of: an oxide, a salt, a pure metal, or an alloy of elements ranging from atomic numbers 21 through 30, 39 through 51, and 57 through 77 and combinations thereof; and carbothermically reacting the precursor mixture to form a ceramic powder, wherein, due to the preparing step, the precursor mixture comprises a sufficient amount of the at least one additive to form the ceramic powder, wherein the ceramic powder comprises: (a) a morphology selected from the group consisting of irregular, equiaxed, plate-like, and combinations thereof; and (b) a particle size distribution selected from the group consisting of fine, intermediate, coarse, and combinations thereof.

Abstract: In one embodiment, the disclosed subject matter relates to an electrolytic cell that has: a cell reservoir; a cathode support retained on a bottom of the cell reservoir, wherein the cathode support contacts at least one of: a metal pad and a molten electrolyte bath within the cell reservoir, wherein the cathode support includes: a body having a support bottom, which is configured to be in communication with the bottom of the electrolysis cell; and a support top, opposite the support bottom, having a cathode attachment area configured to retain a at least one cathode plate therein.

Abstract: In one embodiment, the disclosed subject matter relates to an electrolytic cell that has: a cell reservoir; a cathode support retained on a bottom of the cell reservoir, wherein the cathode support contacts at least one of: a metal pad and a molten electrolyte bath within the cell reservoir, wherein the cathode support includes: a body having a support bottom, which is configured to be in communication with the bottom of the electrolysis cell; and a support top, opposite the support bottom, having a cathode attachment area configured to retain a at least one cathode plate therein.

Abstract: New copper-coated titanium diboride electrodes are disclosed. The copper-coated titanium diboride electrodes may be used in an aluminum electrolysis cell. In one embodiment, a method includes installing the copper-coated titanium diboride electrode in the aluminum electrolysis cell and operating the aluminum electrolysis cell. During start-up, the aluminum electrolysis cell may be preheated and a bath may be formed from a molten electrolyte. Alumina (Al2O3) may in the added to the bath and reduced to aluminum metal. At least some of the copper film of the copper-coated titanium diboride electrode may be replaced by an aluminum film, thereby forming an aluminum-wetted titanium diboride electrode.

Abstract: Systems and methods for making ceramic powders configured with consistent, tailored characteristics and/or properties are provided herein. In some embodiments a system for making ceramic powders, includes: a reactor body having a reaction chamber and configured with a heat source to provide a hot zone along the reaction chamber; a sweep gas inlet configured to direct a sweep gas into the reaction chamber and a sweep gas outlet configured to direct an exhaust gas from the reaction chamber; a plurality of containers, within the reactor body, configured to retain at least one preform, wherein each container is configured to permit the sweep gas to flow therethrough, wherein the preform is configured to permit the sweep gas to flow there through, such that the precursor mixture is reacted in the hot zone to form a ceramic powder product having uniform properties.

Abstract: Systems and methods for making ceramic powders configured with consistent, tailored characteristics and/or properties are provided herein. In some embodiments a system for making ceramic powders, includes: a reactor body having a reaction chamber and configured with a heat source to provide a hot zone along the reaction chamber; a sweep gas inlet configured to direct a sweep gas into the reaction chamber and a sweep gas outlet configured to direct an exhaust gas from the reaction chamber; a plurality of containers, within the reactor body, configured to retain at least one preform, wherein each container is configured to permit the sweep gas to flow therethrough, wherein the preform is configured to permit the sweep gas to flow there through, such that the precursor mixture is reacted in the hot zone to form a ceramic powder product having uniform properties.

Abstract: Systems and methods for making ceramic powders configured with consistent, tailored characteristics and/or properties are provided herein. In some embodiments a system for making ceramic powders, includes: a reactor body having a reaction chamber and configured with a heat source to provide a hot zone along the reaction chamber; a sweep gas inlet configured to direct a sweep gas into the reaction chamber and a sweep gas outlet configured to direct an exhaust gas from the reaction chamber; a plurality of containers, within the reactor body, configured to retain at least one preform, wherein each container is configured to permit the sweep gas to flow therethrough, wherein the preform is configured to permit the sweep gas to flow there through, such that the precursor mixture is reacted in the hot zone to form a ceramic powder product having uniform properties.

Abstract: Systems and methods for making ceramic powders are provided. The method for forming a ceramic powder includes: preparing a precursor mixture, wherein the preparing comprises adding at least one additive to a plurality of reagents, wherein the at least one additive includes at least one of: an oxide, a salt, a pure metal, or an alloy of elements ranging from atomic numbers 21 through 30, 39 through 51, and 57 through 77 and combinations thereof; and carbothermically reacting the precursor mixture to form a ceramic powder, wherein, due to the preparing step, the precursor mixture comprises a sufficient amount of the at least one additive to form the ceramic powder, wherein the ceramic powder comprises: (a) a morphology selected from the group consisting of irregular, equiaxed, plate-like, and combinations thereof; and (b) a particle size distribution selected from the group consisting of fine, intermediate, coarse, and combinations thereof.

Abstract: In some embodiments, a ceramic armor product includes: a ceramic powder; an at least one metal-based additive; and a density of 4.3-4.7 g/cc, wherein the ceramic armor product is substantially lacking grain orientation. In some embodiments, a ceramic armor product, includes: a ceramic powder, wherein the ceramic powder is titanium diboride (TiB2); an at least one metal-based additive, wherein the at least one metal based additive comprises elements ranging from atomic numbers 21 through 30, 39 through 51, and 57 through 77; and a density of 4.3-4.7 g/cc, wherein the ceramic armor product is substantially lacking grain orientation.

Abstract: In one embodiment, the disclosed subject matter relates to an electrolytic cell that has: a cell reservoir; a cathode support retained on a bottom of the cell reservoir, wherein the cathode support contacts at least one of: a metal pad and a molten electrolyte bath within the cell reservoir, wherein the cathode support includes: a body having a support bottom, which is configured to be in communication with the bottom of the electrolysis cell; and a support top, opposite the support bottom, having a cathode attachment area configured to retain a at least one cathode plate therein.