Production of Al-Sc Alloy by Electrolysis from Cryolite Melt Using Secondary Feedstock Material

Electrolysis experiments to produce Al-Sc alloys were carried out in galvanostatic mode using a cryolitic melt with a NaF/AlF3 molar ratio of 2.2 at 980 °C, using both synthetic and waste feeds. After elucidation of the cryolite electrolyte bath chemistry when adding Sc2O3, small-laboratory scale trials allowed for the demonstration of the process and the study and for the optimisation of the electrolysis parameters. Experiments in large-scale electrolysis cells allowed us to run long-term trials in continuous operation, while the on-line monitoring of the cell off-gases ensured the environmentally benign performance of the process. The aluminium product obtained contained 0.6–2.6 wt% Sc, depending on the current density applied. The material is suited to prepare Al-Sc master alloys for 3D printing powders.