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<p>The rising demand for Al–Sc alloys in advanced manufacturing sectors underscores the need for more efficient and cost-effective production methods. Here, we developed a novel molten salt system based on Na<sub>3</sub>AlF<sub>6</sub>-LiF (with a NaF/AlF<sub>3</sub> molar ratio of 2.2) and present an innovative three-stage countercurrent process that, for the first time, achieves the direct one-step aluminothermic reduction of Sc<sub>2</sub>O<sub>3</sub>. The first-stage reaction yields an Al–Sc alloy with 1.82 wt&#xa0;pct Sc, while the complete three-stage process produces a final alloy containing 1.33 wt pct Sc with remarkable 85.72 pct Sc<sub>2</sub>O<sub>3</sub> utilization rate. By systematically elucidating the phase evolution and compositional transformations within the molten salt system during the reaction, and through the optimization of key parameters—including the cryolite-to-Sc<sub>2</sub>O<sub>3</sub> mass ratio (5.2), LiF addition (8 wt pct), and reaction conditions (950&#xa0;°C, 1.5 hours)—we significantly enhance both the reaction kinetics and the alloy quality. Compared to conventional processes, this streamlined method substantially reduces energy consumption and environmental impact, offering a scalable and sustainable pathway for the industrial production of Al–Sc alloys.</p>

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Synthesis of Al–Sc Binary Alloys via Aluminothermic Reduction of Sc2O3 in NaF–AlF3–LiF Flux Systems

  • 期刊论文

  • 发表日期：

    2025年10月21日

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  • Jiuhua Wu,
  • Qunzhao Xu,
  • Zhiqiang Chang,
  • Ji Wang,
  • Jianshe Chen,
  • Qing Han,
  • Shuchen Sun,
  • Daxue Fu

摘要

The rising demand for Al–Sc alloys in advanced manufacturing sectors underscores the need for more efficient and cost-effective production methods. Here, we developed a novel molten salt system based on Na3AlF6-LiF (with a NaF/AlF3 molar ratio of 2.2) and present an innovative three-stage countercurrent process that, for the first time, achieves the direct one-step aluminothermic reduction of Sc2O3. The first-stage reaction yields an Al–Sc alloy with 1.82 wt pct Sc, while the complete three-stage process produces a final alloy containing 1.33 wt pct Sc with remarkable 85.72 pct Sc2O3 utilization rate. By systematically elucidating the phase evolution and compositional transformations within the molten salt system during the reaction, and through the optimization of key parameters—including the cryolite-to-Sc2O3 mass ratio (5.2), LiF addition (8 wt pct), and reaction conditions (950 °C, 1.5 hours)—we significantly enhance both the reaction kinetics and the alloy quality. Compared to conventional processes, this streamlined method substantially reduces energy consumption and environmental impact, offering a scalable and sustainable pathway for the industrial production of Al–Sc alloys.