Separation of Al3Zr Intermetallic Compound from Al–Zr Master Alloy Prepared by Molten Salt Electrolysis

Abstract This paper focuses on preparation of Al–Zr master alloy and Al 3 Zr intermetallic compound. A method is proposed to obtain Al 3 Zr intermetallic compound from Al–Zr master alloy by leaching. The alloy was prepared by electrolysis in 2.4NaF–AlF 3 –5 wt % CaF 2 –5 wt % ZrO 2 cryolite-based electrolyte with the molten Al as cathode and the high purity graphite as anode at 980°C. Zirconium was deposited in the form of solid Al 3 Zr at the bottom of the cathode alloy, and the main phase compositions of the obtained Al-base alloy product were Al phase and Al 3 Zr phase. Then, cube-shaped Al 3 Zr intermetallic compound particles with an average size of 37.8 μm were obtained from the Al–Zr master alloy product by combining alkaline and acidic leaching.