In-situ preparation of alumina-based cermet after reduction of iron oxide in red mud with aluminum dross

Abstract

Aluminum dross (AD) and red mud (RM) are waste discharged from aluminum industry. AD and RM contain 5-15 wt% of hazardous aluminum nitride (AlN) and 20–50 wt% of iron oxide, respectively. In this work, alumina-based cermet was in-situ prepared from AD and RM, after reduction of iron oxide with AlN by pyrometallurgy. Cermet was consisted of metal reinforcement phase about 1 μm, alumina matrix phase and low-melting aluminosilicate binder. Mechanism of in-situ preparation was studied after exploring phase composition of the cermet powder. Iron, silicon and titanium oxide from RM was reduced into Fe3Si and TiN, which acted metal reinforcement phase in cermet. Reaction was consisted of two steps, Fe2O3, TiO2 and AlN dissolving into low-melting aluminosilicate and electron transferring from AlN to Fe2O3, SiO2 and TiO2. Content of Fe in ceramic phase was decreased from 6 at.% to 1 at.% after reduction reaction. Low-melting aluminosilicate acted both reaction solvent for reduction reaction, and binder for metal reinforcement phase and alumina matrix phase. More low-melting aluminosilicate was formed when temperature was increased from 1200 °C to 1400 °C, which made more metal balls be formed. The metal ball and alumina were bonded by low-melting aluminosilicate, which increased the bond strength between reinforcement phase and ceramic phase in cermet. This work achieved a total recycle of AD and RM into cermet. It was proposed a novel idea of in-situ preparing cermet, which was generating metal reinforcement phase in ceramic matrix phase.