Abstract: A series of inventions leading to the production of specific aluminum alloys (especially aluminum beverage can sheet product) through novel approach of introducing, selectively partitioning and managing alloying elements. This invention also enables manufacturing practices to enhance the performance characteristics of aluminum alloys produced. The selected elements can be derived from carbon anodes made from calcined petroleum coke with high metallic contents (such as nickel and vanadium). Alloying elements can also be introduced and managed from other raw material such as alumina and bath constituents added during aluminum smelting process. Additionally, cell operating parameters, such as cell temperature, off gas flow rate, aluminum tapping rate and impurity partition characteristics can also be manipulated to produce low cost aluminum alloys and facilitate utilization of high metallic content calcined petroleum coke.

Abstract: A series of inventions leading to the production of specific aluminum alloys (especially aluminum beverage can sheet product) through novel approach of introducing, selectively partitioning and managing alloying elements. This invention also enables manufacturing practices to enhance the performance characteristics of aluminum alloys produced. The selected elements can be derived from carbon anodes made from calcined petroleum coke with high metallic contents (such as nickel and vanadium). Alloying elements can also be introduced and managed from other raw material such as alumina and bath constituents added during aluminum smelting process. Additionally, cell operating parameters, such as cell temperature, off gas flow rate, aluminum tapping rate and impurity partition characteristics can also be manipulated to produce low cost aluminum alloys and facilitate utilization of high metallic content calcined petroleum coke.

Abstract: A series of inventions leading to the production of specific aluminum alloys (especially aluminum beverage can sheet product) through novel approach of introducing, selectively partitioning and managing alloying elements. This invention also enables manufacturing practices to enhance the performance characteristics of aluminum alloys produced. The selected elements can be derived from carbon anodes made from calcined petroleum coke with high metallic contents (such as nickel and vanadium). Alloying elements can also be introduced and managed from other raw material such as alumina and bath constituents added during aluminum smelting process. Additionally, cell operating parameters, such as cell temperature, off gas flow rate, aluminum tapping rate and impurity partition characteristics can also be manipulated to produce low cost aluminum alloys and facilitate utilization of high metallic content calcined petroleum coke.

Abstract: Methods for the improvement of mechanical properties of aluminum can stock materials. In one method, an aluminum alloy is cast into an ingot, heated at an elevated temperature to homogenize the alloy, hot rolled at an elevated temperature to form hot band material and cold rolled to final gauge. After the heating step, the alloy is hot rolled immediately to minimize the cooling of the alloy between the heating and hot rolling steps.

Abstract: An improved solid carbon reductant comprising partially calcined carbonaceous materials such as petroleum coke, containing relatively low amounts of residual hydrocarbons and a relatively high surface area and thus increased activity as compared to known reductants is provided. This improved reductant is produced by a method comprising heating the carbonaceous material in an oxidizing atmosphere to a temperature of from about 650.degree. C. to about 950.degree. C., preferably from about 800.degree. C. to about 875.degree. C., and most preferably at a temperature about 850.degree. C. In addition, according to the present invention improved chlorination processes are provided using these reductants which result in reduced levels of chlorinated hydrocarbon (C.sub.x Cl.sub.y) production due to reduced residual hydrocarbons. In a preferred embodiment anhydrous aluminum chloride is produced by chlorination of aluminum hexahydrate using the improved reductant.

Abstract: An improved solid carbon reductant comprising partially calcined carbonaceous materials such as petroleum coke, containing relatively low amounts of residual hydrocarbons and a relatively high surface area and thus increased activity as compared to known reductants is provided. This improved reductant is produced by a method comprising heating the carbonaceous material in an oxidizing atmosphere to a temperature of from about 650.degree. C. to about 950.degree. C., preferably from about 800.degree. C. to about 875.degree. C., and most preferably at a temperature about 850.degree. C. In addition, according to the present invention improved chlorination processes are provided using these reductants which result in reduced levels of chlorinated hydrocarbon (C.sub.x Cl.sub.y) production due to reduced residual hydrocarbons. In a preferred embodiment anhydrous aluminum chloride is produced by chlorination of aluminum hexahydrate using the improved reductant.

Abstract: A low porosity coating comprised of at least two layers of material or composites capable of protecting a metal substrate from the corrosive effects of a chlorine-metal chloride environment at temperature values ranging up to 650.degree. C. The first of the two layers has a coefficient of thermal expansion that lies between the metal of the substrate and that of a metal oxide(s) layer disposed upon the first layer. A layer of metal oxide is disposed on the first layer, the metal oxide having a coefficient of expansion somewhat less than the first layer and a minimum solubility in the chlorine-chloride environment. The material or composite of the first layer and the metal oxide of the oxide layer are applied by a technique which sprays particles of the material or composite and metal oxide(s) against a surface at relatively high velocities and temperatures.

Abstract: An improved electrolytic cell is provided for production of a metal such as aluminum by electrolysis of a compound of the metal in a solvent or bath such as molten salt. Electrolysis is carried out by passing a current from an anode to a cathode between which the solvent bath is situated. The cathode comprises a base cathode and cathode extension surfaces comprising graphite and at least 90% refractory hard metal such as titanium diboride. The cathode extension surfaces are produced from a mixture comprising at least 90% refractory hard metal and a carbonaceous binder with little or substantially no particulate carbonaceous material and graphitizing said mixture above 2350.degree. C. to graphitize the carbonaceous material therein to exhibit the graphitic structure.

Abstract: In the production of a metal such as aluminum by electrolysis of an electrolyte bath containing a compound of the metal dissolved therein to produce the metal at a graphite cathode surface, the wear rate of the graphite cathode surface is significantly reduced by incorporating therein selected amounts of certain compounds of aluminum or titanium, especially Al.sub.2 O.sub.3 and TiO.sub.2. The improvement is particularly suited to the production of aluminum from chloroaluminate electrolyte baths.

Abstract: A metal such as aluminum is produced by electrolysis of a compound of the metal in a solvent or bath such as molten salt. Electrolysis is carried out by passing a current from an anode to a cathode between which the solvent bath is situated. The cathode is composed of a composite comprising graphite and a refractory hard metal such as titanium diboride. The properties and performance of the composite cathode are improved through careful manufacturing controls and selectivity with respect to electrode configuration and cell operating conditions.

Abstract: A metal such as aluminum is produced by electrolysis of a compound of the metal in a solvent such as a molten salt. Electrolysis is carried out by passing a current from an anode to a cathode between which the solvent bath is situated. The cathode or cathode member is composed of a graphite substrate coated with a refractory hard metal such as titanium diboride. The coating adhesion of the TiB.sub.2 is improved through control of the manufacture and structure of the graphite substrate to favor a higher coefficient of thermal expansion and to have the density of the graphite fall within a range of 1.6 to 1.85 grams per cubic centimeter. The steps in producing the graphite may include working it so as to provide a grain direction. One embodiment includes aligning the refractory hard metal coated graphite in the electrolytic cell with the graphite grain direction parallel to the direction of current flow from anode to cathode.

Abstract: Chlorination of aluminous materials such as alumina and bauxite is carried out at 575.degree. to 750.degree. C. in the presence of a solid reducing agent. The reducing agent is a green coke which has been calcined at a temperature between 650.degree. C. and 900.degree. C. for a period of from 10 to 120 minutes.

Abstract: A carbonaceous electrode for use in a bipolar electrolytic cell is treated on one side with a source of aluminum to form an adherent layer of aluminum carbide thereon. The electrode is arranged in the cell such that on the passage of electrolyzing current the treated surface functions as a cathode. On electrolyzing the cell, chlorine is produced on each anode surface and aluminum is produced on each cathode surface.

Abstract: Metal such as aluminum is produced electrolytically from metal chlorides or other halides dissolved in a molten solvent bath of higher decomposition potential in a cell including one or more carbonaceous or graphite cathode surfaces spaced from opposed anodes, particularly a bipolar cell, with bath flow through the spaces between the anodes and cathodes. The wetting characteristics of the graphite cathode with respect to the metal deposited there by electrolysis are selectively balanced with the bath flow over the cathode and with the anode-to-cathode distance. Cathode surface wear rate is substantially reduced if the surface is wettable by the metal in regions of low bath flow velocity or regions of greater anode-cathode distance. The wear rate is also reduced by using a non-wettable cathode surface in regions of higher bath flow velocity or regions of closer anode-cathode distance.

Abstract: Metal such as aluminum is produced electrolytically from metal chlorides or other halides dissolved in a molten solvent bath of higher decomposition potential in a cell including one or more graphite cathode surfaces spaced from opposed anodes, particularly a bipolar cell, with bath flow through the spaces between the anodes and cathodes. The wetting characteristics of the carbonaceous cathode with respect to the metal deposited there by electrolysis are selectively balanced with the bath flow over the cathode and with the anode-to-cathode distance. Cathode surface wear rate is substantially reduced if the surface is wettable by the metal in regions of low bath flow velocity or regions of greater anode-cathode distance. The wear rate is also reduced by using non-wettable cathode surfaces in regions of higher bath flow velocity or regions of closer anode-cathode distance.

Abstract: A method is provided for removing aluminum or compounds thereof causing a short circuit in an electrolytic cell containing aluminum chloride dissolved in a molten solvent of higher decomposition potential, the cell used for the production of aluminum from aluminum chloride and having a terminal anode and cathode providing an inter-electrode space therebetween. The method comprises removing aluminum chloride and molten solvent from the cell to an extent which exposes the materials in the inter-electrode space causing the short circuit, introducing a source of chlorinating agent to the cell and contacting the materials causing the short circuit with the chlorinating agent to form aluminum chloride, the contacting being for a time sufficient to remove the short circuit thereby permitting the addition of the aluminum chloride and solvent and the electrolysis thereof for the production of aluminum.

Abstract: A process is provided for producing aluminum in an electrolytic cell containing aluminum chloride dissolved in a molten solvent of higher decomposition potential. The cell has a terminal anode, a terminal cathode and a bipolar electrode arranged to operate with the anode and the cathode, providing interelectrode spaces therebetween. On electrolyzing the cell chlorine is produced on each anode surface thereof and aluminum on each cathode surface, the aluminum being swept from the cathode surface by bath material. In the process, carbonaceous material is provided for use as the electrode. The direction of grain flow constituting the carbonaceous material is determined and the electrode is arranged in the cell such that the direction of electrolysis current flow through the cell is in a direction substantially perpendicular to the direction of grain flow in the electrode.

Abstract: A process for purifying aluminum alloys comprises providing molten aluminum alloy in a container having a porous wall therein capable of containing molten aluminum in the container and being permeable by the molten electrolyte. Aluminum is electrolytically transported through the porous wall to a cathode thereby substantially separating the aluminum from alloying constituents.

Abstract: A process for the production of aluminum chloride comprises providing a mixture of high purity activated carbon and alumina and bubbling chlorine gas therethrough, the mixture being kept at a temperature in the range of 500.degree. to 775.degree. C. Aluminum chloride is removed from the mixture as a vapor and condensed.

Abstract: A process for purifying aluminum alloys comprises providing molten aluminum alloy in a container having a porous wall therein capable of containing molten aluminum in the container and being permeable by the molten electrolyte. Aluminum is electrolytically transported through the porous wall to a cathode thereby substantially separating the aluminum from alloying constituents.