Abstract: Methods for manufacturing components that include casting a first melt to produce an ingot, remelting the ingot to form a second melt, forming a powder from the second melt using an atomization process, and fabricating a component utilizing the powder in an additive manufacturing process. The ingot and the powder include an aluminum matrix that contains dispersions of TiB2 particles and Al3Ti particles and the component is a metal matrix composite having an aluminum matrix that contains dispersions of TiB2 particles and Al3Ti particles. Optionally, the metal matrix composite may include particles of an intermetallic compound of aluminum and at least one alloying element.

Abstract: Provided are a method and an apparatus for melting an aluminum powder, which are capable of melting the aluminum powder with a high yield and allow the melted aluminum to be reused for a variety of applications. The method for melting the aluminum powder includes the steps of: preparing a mixture (M) including an aluminum powder (A) and a fluoride-based flux (F) by previously mixing the aluminum powder (A) and the fluoride-based flux (F); and melting the mixture (M) in molten aluminum (L).

Abstract: Composition for releasing sodium or strontium or both into molten aluminum or aluminum-based alloy. The composition is formed by fusing a mixture containing at least two salts, at least one of the salts having sodium as a cation and/or at least one of the salts having strontium as a cation, at least one of the salts having carbonate as an anion and at least one of the salts having a halide as an anion. The composition may be employed as a modifying flux for altering the microstructure of aluminum and aluminum alloy.

Abstract: A method for purifying Al—Ti—B) alloy melt includes putting and melting industrial aluminum ingot in an electromagnetic induction smelting furnace, the melt of Al being covered by a high-temperature covering agent, and its temperature up to at about 670˜900° C.; adding material of K2TiF6 and KBF4 into the smelting furnace and then stirring the compounds therein to react; adding compound comprising Mg, L, Na and F to the evenly stirred K2TiF6 and KBF4, the compound having an amount about 0.01%˜1% of a sum weight of total K2TiF6 and KBF4, and uniformly stirring for about 15˜60 minutes under a reaction temperature being constantly at about 670˜900° C., the dregs being removed, the Al alloy being casting molded.

Abstract: A method for the purification of a metal selected from the group consisting of aluminum and aluminum alloys, wherein the metal is in a liquid phase and is contacted with a salt flux consisting of a binary mixture of NaCl and MgCl2. Preferably, more than 22% by weight of the binary mixture consists of NaCl.

Abstract: A process is provided for producing an aluminium-titanium-boron grain refining master alloy containing titanium boride and titanium aluminide particles, the process comprising melting aluminium in a silicon carbide crucible in a medium frequency induction or an electric resistance furnace, adding to the melt at a temperature between 750 degrees Celsius and 900 degrees Celsius, KBF4 and K2TiF6 salts, pre-mixed in proportions to obtain a Ti/B ratio of 5 in the melt, gently mixing the salt mixture with the melt without introducing any stirring, transferring the molten alloy to an electric resistance furnace maintained at 800 degrees Celsius, decanting the K—Al—F salt, the by-product of the salt reaction, thoroughly stirring the molten alloy in the SiC crucible with graphite rods before finally casting the molten alloy into cylindrical molds in the form of billets and finally extruding the billet into 9.5 mm rods.

Abstract: A molten aluminum alloy processing method is intended use sludge produced by the zinc phosphate treatment of sructures including those of aluminum alloys effectively as a flux for molten aluminum alloy processing. The flux contains 3 to 30% by mass fluorine-equivalent metal fluorides, 40 to 90% by mass metal phosphates (8 to 18% by mass P) and 50% by mass or below inorganic salts. The sum of contents of the inorganic salts and metal phosphates is 90% by mass or below.

Abstract: A salt flux composition comprising a high purity salt and additives is used in the recycle of scrap aluminum to increase the recovery of aluminum. The additives include an alkaline agent and a fluoride source.

Abstract: Improved apparatus and method are described for the removal of light metals; sodium, lithium, calcium and magnesium, from virgin aluminum tapped from a Hall Heroult reduction cell using LiF-modified or LiF+MgF2 electrolyte. The method is performed in a crucible or at a station intermediate between the cells and furnaces in a cast house. Fine particulate aluminum fluoride and/or sodium aluminum tetrafluoride are transported by a gas or gas mixture into the molten aluminum in a manner such that the light metals are preferentially removed or their concentration substantially lowered through: a) the axle of a specially designed spinning impeller; b) partially through the axle of a specially designed spinning impeller and partially through one or more pipes equipped with dispersers for dispersing into the molten metal flow close to the spinning impeller; or c) through one or more pipes equipped with dispersers for dispersing into the molten metal flow close to the impeller fastened to a solid axle.

Abstract: An improved method of eliminating phosphorus and/or antimony from molten aluminum containing phosphorus and/or antimony is provided, including the step of adding magnesium or calcium to the molten aluminum maintained at a temperature of 650° to 850° C. while blowing chlorine gas or a chloride thereinto, to remove the phosphorus and/or the antimony contained in the molten aluminum.

Abstract: The invention provides a process for producing an aluminium-based matrix melt, having boride particles dispersed therein, which is castable, and yet when cast produces a product having a surprisingly good combination of mechanical properties such as stiffness, strength, and elongation at failure. In the process, precursors for boride particles are reacted within an aluminium-based melt to produce boride ceramic particles such as titanium diboride, the process being carried out under conditions such that the melt remains fluid.

Abstract: A salt flux composition comprising a high purity salt and additives is used in the recycle of scrap aluminum to increase the recovery of aluminum. The additives include an alkaline agent and a fluoride source.

Abstract: A salt flux composition comprising a standard purity salt and additives is used in the recycle of scrap aluminum to increase the recovery of aluminum. The additives include a carbon source, an alkaline agent and a fluoride source.

Abstract: A novel method for producing a ceramic phase particle dispersoid in metal and a novel product composed thereof. The method includes (a) providing a molten composition consisting essentially of molten aluminum alloy containing molten metal selected from the group consisting of Zr, V and combinations thereof, (b) providing a chloride salt containing fine carbon particles; and (c) reacting the chloride salt containing fine carbon particles in the molten aluminum metal with the molten metal to form a uniform distribution of finely sized carbide particles formed and dispersed in-situ in an aluminum alloy matrix.

Abstract: There is provided an improved method for dispersing a treatment media in a body of molten metal using an impeller to disperse the media in the body of molten metal, the method producing increased shear forces in the body of molten metal and reducing vortex formation. The method comprises the steps of providing a body of molten metal and an impeller on a shaft in the body. A treatment media is added to the body and dispersed by rotating said impeller in one direction and thereafter reversing the direction of rotation of the impeller to a counter direction. The direction of rotation of the impeller is reversed periodically to substantially reduce formation of a vortex around the shaft of the impeller and to provide increased shear forces in the body for purposes of improving treatment of the molten metal by improved dispersion of the media therein.

Abstract: Disclosed is an improved flux comprising 32 to 61 wt. % sodium chloride, 2 to 15 wt. % magnesium chloride, 2 to 12 wt. % carbon, the remainder potassium chloride.

Abstract: There is provided an improved method for dispersing a treatment media in a body of molten metal using an impeller to disperse the media in the body of molten metal, the method producing increased shear forces in the body of molten metal and reducing vortex formation. The method comprises the steps of providing a body of molten metal and an impeller on a shaft in the body. A treatment media is added to the body and dispersed by rotating said impeller in one direction and thereafter reversing the direction of rotation of the impeller to a counter direction. The direction of rotation of the impeller is reversed periodically to substantially reduce formation of a vortex around the shaft of the impeller and to provide increased shear forces in the body for purposes of improving treatment of the molten metal by improved dispersion of the media therein.

Abstract: Disclosed is a method of adding silicon to aluminum. The method is characterized in that silicon particles having a diameter ranging between 2 mm and 50 mm are added to a molten aluminum together with a flux represented by the general formula XaMFb, where "X" represents an element included in the third or fourth period of the Periodic Table, "M" is a III or IV group element of the Periodic Table, and "F" is fluorine. A part of the flux may be added in the form of coating on the surface of the silicon particle.

Abstract: A continuous process is described for the production of an aluminum master alloy, e.g. an Al-Ti-B grain refining rod, in which molten aluminum is continuously passed through a confined reaction zone. Particulate titanium and/or boron precursor compounds, e.g. salts, are continuously added to the molten aluminum in the reaction zone and the content of the reaction zone is continuously stirred to submerge the salts within the aluminum melt and form an alloy therewith. A mixture of formed molten alloy and entrained reaction products is continuously transferred from a lower region of the reaction zone into a refining zone, with reaction product slag being collected on the surface of the molten alloy in the refining zone. The molten alloy formed is continuously transferred via a transfer conduit from the refining zone to a casting station.

Abstract: A method for removing dissolved alkali metals and alkaline earth metals from aluminum is disclosed. The method comprises providing a body of molten aluminum containing the alkali metal and alkaline earth metals in a container and inductively moving the molten aluminum in upper regions of the body in a generally downward direction at outward regions of the body and in a generally upward direction in inner regions of the body. Fluoride values are added to the body to react with the alkali metals or alkaline earth metals.

Abstract: Aluminum and aluminum alloy melts are purified by removing entrained gaseous impurities and solid particulate impurities, primarily aluminum oxides, by bubbling a non-corrosive intimate mixture of sulfur hexafluoride in an inert gas. Magnesium levels, if present, are not significantly reduced. The process is reliable and the gas mixture safe for aluminum purifying operations and procedures.

Abstract: Spent potlinings from aluminum reduction cells are fed to an aluminum reclamation furnace as a partial replacement for or supplement to the molten salt flux used in the reclamation process. This rids the spent potlinings of materials which would leach into soil or groundwater if the potlinings were otherwise disposed of at dumpsites, rendering them suitable for dumping with no hazard to the environment. Benefits to the reclamation process may be had at the same by substituting the less expensive potlinings for the salt flux materials and by using the fuel potential of the potlinings to reduce the external fuel requirement.