Static Crystallization, an Alternative Methodology for Synthesis of High-Purity Aluminum

Due to its outstanding properties and wide range of applications, high-purity to ultra-high-purity aluminum represents a strategic material for meeting the future challenges of the 21st century. The purification of aluminum towards higher purity levels is usually performed via a combination of three-layer electrolytic refining and fractional crystallization using zone-melting processes. New methods and processes are being researched in the search for more time-saving and less costly options. Metal refining using static crystallization represents one of these new, alternative processes. This work investigated the feasibility of metal refining by means of a static crystallization furnace using aluminum as an example metal. In particular, the effects of the temperature gradient and the cooling rate on the reduction factor of the impurities iron (Fe), silicon (Si), and lead (Pb) were investigated. In addition, the effects of the process parameters on the grain structure formed were investigated, and correlations to the resulting purity level were made.

Automated summary

Due to its excellent properties, high-purity to ultra-high-purity aluminum is considered a strategic material to meet future challenges. Current purification methods include electrolytic refining and fractional crystallization. New alternative methods, such as static crystallization, are being researched for more efficient and cost-effective options. This study focused on the feasibility of metal refining using a static crystallization furnace, specifically investigating the effects of temperature gradient, cooling rate, and process parameters on impurity reduction and resulting grain structure.