Use of rapid solidification in processing of aluminum alloys with reduced deep-sea nodules

Abstract

Ferromanganese nodules represent an industrially untapped source of valuable metals (Mn, Cu, Ni, Ti, Co) but are still just the object of scientific research. In comparison with already utilized rocks, deep-sea deposits are too hard to reach for their full-scale mining to be profitable. Despite of this, current marine engineering allows us to conduct complete exploration and obtain mineral samples. We can already now develop low-cost methods for subsequent processing in anticipation of improved and safer future mining technology. But in what form would be the final product the most applicable? In our study, we reduced the pyro metallurgical pretreatment of raw nodules to two simple steps: roasting and aluminothermic reduction. Then we added a product, manganese-based alloy, to pure aluminum as a new alloying additive. As a reference for experimental alloys, commercial cast AlMn10 master alloy was chosen. The tested samples were prepared using two advanced operations of powder metallurgy: melt-spinning and spark plasma sintering (SPS). Microstructure was described in detail, tribological and selected mechanical properties were measured, and a comparative analysis was conducted. New additive gradually improved properties of alloys to a level close to 3xxx industrial alloys with its increasing percentage in pure aluminum. Measured values did not surpass the referent AlMn10, but there was not recorded any adverse impact associated with the origin of alloying mixture.