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<p>The present study investigates the role of alloying elements such as manganese and chromium in enhancing the efficient separation of Fe in Al-Fe-Si alloys via a gravity sedimentation technique. The effectiveness of separating Fe-containing intermetallic phases is influenced not only by the concentrations of Mn, Cr, and Si but also by key parameters like holding temperature and settling time. The CALPHAD approach, utilizing ThermoCalc, was employed to identify the optimal temperature for the formation of Fe-rich intermetallic phases in the experimental alloys. The addition of Mn and Cr helps the formation of these dense Fe-rich intermetallic phases in the alloy, while elevated Si content reduces the solidification temperature of the α-Al phase and widens the temperature window for the formation of Fe-rich intermetallic phases, thereby accelerating their sedimentation. A notable reduction (&gt; 70%) in the contents of both Fe and Mn was observed within 1&#xa0;h when chromium was added to high-Fe aluminum alloys. Following the laboratory-scale findings, large-scale trials were conducted, demonstrating a successful replication of the experimental results in industrial-scale production.</p>

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Influence of Si, Mn, and Cr on the Iron Removal from Aluminum Scrap: A Thermodynamic and Experimental Analysis

  • 期刊论文

  • 发表日期：

    2025年8月27日

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  • Manish Kumar Sinha,
  • Brajendra Mishra,
  • Subodh Kumar Das,
  • Tom Grosko

摘要

The present study investigates the role of alloying elements such as manganese and chromium in enhancing the efficient separation of Fe in Al-Fe-Si alloys via a gravity sedimentation technique. The effectiveness of separating Fe-containing intermetallic phases is influenced not only by the concentrations of Mn, Cr, and Si but also by key parameters like holding temperature and settling time. The CALPHAD approach, utilizing ThermoCalc, was employed to identify the optimal temperature for the formation of Fe-rich intermetallic phases in the experimental alloys. The addition of Mn and Cr helps the formation of these dense Fe-rich intermetallic phases in the alloy, while elevated Si content reduces the solidification temperature of the α-Al phase and widens the temperature window for the formation of Fe-rich intermetallic phases, thereby accelerating their sedimentation. A notable reduction (> 70%) in the contents of both Fe and Mn was observed within 1 h when chromium was added to high-Fe aluminum alloys. Following the laboratory-scale findings, large-scale trials were conducted, demonstrating a successful replication of the experimental results in industrial-scale production.