A multimaterial based on metallic copper and spinel oxide made by powder bed laser fusion: A new nanostructured material for inert anode dedicated to aluminum electrolysis

Abstract

Coherent 3D parts of cermets, made of spinel ferrite and metallic copper, are prepared in a nitrogen atmosphere by powder bed additive manufacturing of a mixture of oxide and metallic powders. The cermets obtained are constituted by the association of blocks of about 500 μm, which create between them, a relatively large porosity (# 35%). Each block is subdivided into intimately nested zones that are either predominantly metallic or predominantly oxide type. In the metal parts, a dispersion of oxide crystals is observed, whose size varies from ten nanometers to a few micrometers. A similar distribution of metal particles in the oxide zones is also demonstrated. The chemical compositions of metallic and oxide phases are slightly different from those in the initial powders. Due to the high energy density of the laser, the melting temperature of the metal and oxides could be reached and therefore this could explain the chemical composition variations in the phases and the shape of oxide and metallic nanometric grains. The process used can therefore be described as powder bed fusion. These nanostructured cermets have been used as inert anodes for the electrolysis of aluminum in molten cryolite. Although penalized by a high porosity, 5 mm in diameter anodes allowed to carry out an electrolysis for 4 h. Since Spark Plasma Sintering can greatly reduce their porosity, while retaining their specific microstructure, the implementation of additive manufacturing for producing inert anodes is therefore of real interest.