Production of the Al–B master alloy by KBF4and B 2O3aluminothermic reduction in molten salt flux medium

The study covers the process of obtaining the Al–B master alloy by the KBF4and B2O3aluminothermic reduction using KF–AlF3and KF–NaF–AlF3fluoride fluxes at 983 and 1123 К, respectively, and KCl–NaCl–KF chloride-fluoride fluxes at Т= 1173÷1223 К. All experiments were carried out under the same conditions: molten mixture stirring rate was 400 rpm, synthesis duration was 30min. The maximum amount of boron (1,5 %) in the Al–B alloy was obtained when using KBF4(3 % per B) as a boron-containing raw material in the KF–AlF3medium with a molar (cryolite) ratio (CR) of KF/AlF3equal to 1,3, atТ= 983 К, while boron recovery ratio did not exceed 75 %. Comparable results were obtained in experiments with KF–NaF–AlF3f lux (CR = 1,5) at Т= 1123 К. However, with the increased concentration of fed boron its recovery ratio decreased substantially. It is connected with the higher decomposition temperature of not only KBF4, but also less thermally stable NaBF4 formed as a result of exchange reaction in the melt. Therefore it is not recommended to use sodium salts as a f lux component. The Al–B master alloys obtained by KBF4reduction in fluoride fluxes were solid solutions of B in Al containing the AlB2intermetallic compound. The lowest amount of boron in aluminum with the minimum degree of extraction was obtained in experiments with the B2O3in molten KF–AlF3with CR = 1,5. Nevertheless, the results of scanning electron microscopy indicate a uniform distribution of B over the Al matrix and the absence of intermetallic compounds, while a large amount of Al2O3was found, which is the product of B2O3reactions with both liquid Al and KF–AlF3flux.