Dissolution Mechanism for High Melting Point Transition Elements in Aluminum Melt

Abstract

When added cold in aluminum melt, the alloying process for compacts of transition metal elements such as Mn, Fe, Cr, Ni, Ti, Cu, and Zn takes a sequence of incubation, exothermic reactions to form intermetallic compounds, and dispersion of the alloying elements into aluminum melt. The experiments with Cr compacts show that the incubation period is affected by the content of ingredient Al and size of compacts and by size of Cr particles. Incubation period becomes longer as the content of ingredient aluminum in compact decreases, and this prolonged incubation period negatively impacts the dissolution of the alloying elements in aluminum. Once liquid aluminum forms at reaction sites, the exothermic reaction takes place quickly and significantly raises the temperature of the compacts. As the result of it, the compacts swell in volume with a sponge like structure. Such porous structure encourages the penetration of liquid aluminum from the melt. The compacts become weak mechanically, and the alloying elements are dispersed and entrained in aluminum melt as discrete and small sized units. When Cr compacts are deficient in aluminum, the unreacted Cr particles are encased by the intermetallic compounds in the dispersed particles. They are carried in the melt flow and continue the dissolution reaction in aluminum. The entire dissolution process of Cr compacts completes within 10 to 15 minutes with a full recovery when the aluminum content is 10 to 20% in compacts.