IP Library › Granted Patent US 12,529,157
Granted Patent B2
US 12,529,157 · App. 18/623,827 · Granted Jan 20, 2026

Method of aluminum-scandium alloy production

Inventors: Adam Clayton Powell (Newton, MA); Matthew R. Earlam (Lakewood, CO); Salvador A. Barriga (Cambridge, MA); Richard Salvucci (Stoughton, MA); Brian Hunt (Woburn, MA)
Assignee: NioCorp Advanced Metals and Alloys, LLC
C25C3/36C22C21/00C25C7/02C25C7/06
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Quick Facts
Patent No.
US 12,529,157
App. No.
18/623,827
Granted
Jan 20, 2026
Kind
B2
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 ScF 3 or AlF 3 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 Sc 2 O 3 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.

Claims (35)

1 . A method of producing an aluminum-scandium (Al—Sc) alloy, comprising:

(a) providing an electrolyte bath comprising a first portion of at least one of ScF 3 or AlF 3 and a first portion of at least one of LiF, NaF, or KF;

(b) providing a cathode in electrical contact with the electrolyte bath, wherein the cathode comprises aluminum;

(c) providing an anode in electrical contact with the electrolyte bath;

(d) adding a first portion of Sc 2 O 3 into the electrolyte bath;

(e) reacting an aluminum ion with the cathode; and

(f) applying an electric current to the cathode, thereby reacting a scandium ion with the cathode to produce the Al—Sc alloy, wherein after reacting the scandium ion with the cathode:

the electrolyte bath comprises ScF 3 , AlF 3 , and at least one of LiF, NaF, or KF, and

the cathode comprises the aluminum and scandium.

2 . The method of claim 1 , wherein the Al—Sc alloy comprises between about 5-12 weight % scandium.

3 . The method of claim 1 , wherein the Al—Sc alloy comprises between about 8-12 weight % scandium.

4 . The method of claim 1 , wherein at least a portion of the aluminum and the scandium in the cathode is a liquid.

5 . The method of claim 1 , wherein the electric current to the cathode has a current density of about 0.2-1.0 A/cm 2 .

6 . The method of claim 1 , further comprising:

maintaining a predetermined molar ratio of the scandium ion to the aluminum ion of about 0:1 to about 2:1, wherein the predetermined ratio is maintained by controlling the electric current to the cathode.

7 . The method of claim 1 , further comprising:

maintaining a predetermined molar ratio of an oxygen ion to a fluoride ion of about 1:20 to about 1:250, wherein the predetermined ratio of the oxygen ion to the fluoride ion is maintained by:

controlling the electric current, or

adding a second portion of Sc 2 O 3 into the electrolyte bath.

8 . The method of claim 1 , further comprising:

maintaining a predetermined molar ratio of a lithium ion to the scandium ion and the aluminum ion of about 0.5:1 to about 4:1, wherein the predetermined molar ratio is maintained by adding a second portion of LiF.

9 . The method of claim 1 , further comprising:

maintaining a predetermined molar ratio of a sodium ion to the scandium ion and the aluminum ion of about 0.5:1 to about 6:1, wherein the predetermined molar ratio is maintained by adding a second portion of NaF.

10 . The method of claim 1 , further comprising:

maintaining a predetermined molar ratio of a potassium ion to the scandium ion and the aluminum ion of about 0.5:1 to about 6:1, wherein the predetermined molar ratio is maintained by adding a second portion of KF.

11 . The method of claim 1 , further comprising:

adding a second portion of Sc 2 O 3 , AlF 3 , and a second portion of at least one of LiF, NaF, or KF into the electrolyte bath.

12 . The method of claim 11 , wherein the second portion of Sc 2 O 3 , AlF 3 , and the second portion of at least one of LiF, NaF, or KF are added such that the electrolyte bath comprises about 17-38 weight % ScF 3 , about 15-28 weight % AlF 3 , about 43-55 weight % NaF, and about 1-5 weight % Sc 2 O 3 .

13 . The method of claim 11 , wherein the second portion of Sc 2 O 3 , AlF 3 , and the second portion of at least one of LiF, NaF, or KF are added such that the electrolyte bath comprises about 22-45 wt % ScF 3 , about 18-33 wt % AlF 3 , about 31-43 wt % LiF, and about 1-6 wt % Sc 2 O 3 .

14 . The method of claim 11 , wherein the second portion of Sc 2 O 3 , AlF 3 , and the second portion of at least one of LiF, NaF, or KF are added such that the electrolyte bath comprises about 14-32 wt % ScF 3 , about 12-24 wt % AlF 3 , about 51-63 wt % KF, and about 1-5 wt % Sc 2 O 3 .

15 . The method of claim 1 , further comprising:

adding a second portion of Sc 2 O 3 , ScF 3 , AlF 3 , and a second portion of at least one of LiF, NaF, or KF into the electrolyte bath.

16 . The method of claim 15 , wherein the second portion of Sc 2 O 3 , ScF 3 , AlF 3 , and the second portion of at least one of LiF, NaF, or KF are added such that the electrolyte bath comprises about 17-38 weight % ScF 3 , about 15-28 weight % AlF 3 , about 43-55 weight % NaF, and about 1-5 weight % Sc 2 O 3 .

17 . The method of claim 15 , wherein the second portion of Sc 2 O 3 , ScF 3 , AlF 3 , and the second portion of at least one of LiF, NaF, or KF are added such that the electrolyte bath comprises about 22-45 wt % ScF 3 , about 18-33 wt % AlF 3 , about 31-43 wt % LiF, and about 1-6 wt % Sc 2 O 3 .

18 . The method of claim 15 , wherein the second portion of Sc 2 O 3 , ScF 3 , AlF 3 , and the second portion of at least one of LiF, NaF, or KF are added such that the electrolyte bath comprises about 14-32 wt % ScF 3 , about 12-24 wt % AlF 3 , about 51-63 wt % KF, and about 1-5 wt % Sc 2 O 3 .

Assignments (4)
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Dec 12, 2025
From: FEA MATERIALS LLC
To: NIOCORP ADVANCED METALS AND ALLOYS, LLC
Reel/Frame 073205/0465 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Nov 12, 2024
From: INFINIUM, INC.
To: FEA MATERIALS LLC
Reel/Frame 069359/0918 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Nov 12, 2024
From: POWELL, ADAM CLAYTON; EARLAM, MATTHEW R.; BARRIGA, SALVADOR A.; SALVUCCI, RICHARD
To: INFINIUM, INC.
Reel/Frame 069225/0675 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Nov 12, 2024
From: HUNT, BRIAN
To: FEA MATERIALS LLC
Reel/Frame 069228/0631 →
Continuity (3)
Continuation 16980957
Provisional Application 62643301 · Mar 15, 2018
Related Publication 20250059663A1 · Feb 20, 2025
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