Direct scandium alloying
View Patent ↗A method is provided for forming a metal alloy. The method includes preparing a mixture of scandium oxide and a flux, thereby obtaining a flux-oxide mixture, wherein the flux contains less than 20% fluoride by weight, based on the total weight of the flux; mixing the flux-oxide mixture with molten aluminum, thereby obtaining a flux-metal mixture; cooling the flux-metal mixture; and separating at least a portion of the flux from the flux-metal mixture, thereby obtaining a metal alloy.
1. A method for forming a metal alloy, comprising:
producing a first molten metal having a temperature of at least 780° C., wherein the first molten metal is selected from the group consisting of aluminum and aluminum alloys;
preparing a mixture of scandium oxalate and a flux, thereby obtaining a flux-oxalate mixture;
adding the flux-oxalate mixture to the first molten metal, thereby obtaining a second molten metal; and
stirring the second molten metal;
wherein the second molten metal is stirred only after at least 85% of the at least one gaseous byproduct has been evolved.
2. The method of claim 1 , wherein adding the flux-oxalate mixture to the first molten metal generates at least one gaseous byproduct.
3. The method of claim 2 , wherein the second molten metal is stirred only after at least 90% of the at least one gaseous byproduct has been evolved.
4. The method of claim 2 , wherein the second molten metal is stirred only after at least 95% of the at least one gaseous byproduct has been evolved.
5. The method of claim 2 , wherein the at least one gaseous byproduct is selected from the group consisting of carbon monoxide and carbon dioxide.
6. The method of claim 1 , wherein adding the flux-oxalate mixture to the molten metal includes applying the flux-oxalate mixture to the surface of the molten metal.
7. A method for forming a metal alloy, comprising:
preparing a mixture of scandium oxalate and a flux, thereby obtaining a flux-oxalate mixture;
melting the flux-oxalate mixture to produce a fused product;
producing a first molten metal having a temperature of at least 780° C., wherein the first molten metal is selected from the group consisting of aluminum and aluminum alloys;
adding the fused product to the first molten metal, thereby obtaining a second molten metal; and
stirring the second molten metal;
wherein the fused product is added to the first molten metal only after at least 85% of the at least one gaseous byproduct has been evolved.
8. The method of claim 7 , wherein melting the flux-oxalate mixture includes heating the flux-oxalate mixture to a temperature within the range of 700−900° C.
9. The method of claim 7 , wherein melting the flux-oxalate mixture generates at least one gaseous byproduct.
10. The method of claim 9 , wherein the fused product is added to the first molten metal only after at least 90% of the at least one gaseous byproduct has been evolved.
11. The method of claim 9 , wherein the fused product is added to the first molten metal only after at least 95% of the at least one gaseous byproduct has been evolved.
12. The method of claim 9 , wherein the at least one gaseous byproduct is selected from the group consisting of carbon monoxide and carbon dioxide.
13. The method of claim 7 , further comprising:
stirring the molten flux-oxalate mixture.
14. The method of claim 7 , wherein the flux-oxalate mixture is melted in a vessel equipped to retain calcining oxalate.
15. The method of claim 7 , further comprising:
pouring the fused product onto a surface; and
allowing the poured, fused product to cool.
16. The method of claim 15 , wherein adding the fused product to the first molten metal includes applying the fused product to the surface of the molten metal.