Documente Academic
Documente Profesional
Documente Cultură
ABSTRACT
For various reasons, molten salts, mainly chlorides and fluorides, are used in the
aluminum industry. In the holding and melting furnaces, these salts may have different
roles such as protecting the metal from oxidation, reducing the metal content of the skim
or removing inclusions or impurities from the metal bath. However, the use of these salts
may also have some undesirable effects such as easy attack of the furnace lining
refractory materials by molten aluminum.
The aim of the present investigation was to clarify and to compare the effects of
chloride versus fluoride salts, on the corrosion process of the aluminosilicate based
refractory materials. A laboratory test and procedure, simulating the conditions at the
metal line in the aluminum treatment furnaces, was used. Different aluminum alloys (Al5wt.%Mg, Al-5.5wt.%Zn and 7075 alloy) and chloride or fluoride salts (MgCl2, KCl,
CaCl2, NaCl, MgF2, CaF2, NaF and cryolite) were used as well as several aluminosilicate
materials. Thermogravimetric measurements were also carried out in order to analyze the
effect of the salts on the oxidation of molten aluminum alloys. The experimental results
showed that fluoride salts are more aggressive than chlorides against the tested refractory
products. It is postulated that the fluorides prevent the formation of a protective oxide
layer on the metal surface, favoring at the same time the corrosion of refractories.
Moreover, it was found that the presence of Na in fluoride salts increases significantly the
aggressiveness of the aluminum alloy towards the refractory samples.
INTRODUCTION
EXPERIMENTAL PROCEDURES
cavity (diameter: 38 mm, depth: 50 mm) is then drilled in the cubes to obtain crucible
samples, which are required for CIREP laboratory Bellyband test. The cavity of samples
is filled, at room temperature, with about 100 g of aluminum alloys. Most of the tests
were performed with a laboratory prepared Al-5wt.%Mg alloy. Some tests were carried
out with Al-5.5wt.%Zn and commercial 7075 alloys, which contain 5.5wt.%Zn,
2.5wt.%Mg and 1.6wt.%Cu. The salts and small pieces of corundum (nuclei) are added
on the surface of the alloy, at room temperature. The addition of salts (normally less than
0.5 g) is made in the manner to cover approximately the of the surface of the metal and
thus to allow some direct contact between the metal and the atmosphere. As mentioned
before, chloride or fluoride-based salts (MgCl2, KCl, CaCl2, NaCl, MgF2, CaF2, NaF and
cryolite Na3AlF6) are used in this work.
Table I - Chemical Compositions (in wt.%) of the Tested Refractory Materials
Al2O3
Fe2O3
CaO
TiO2
Material
SiO2
C-8090
11.4
79.2
1.08
1.16
2.04
C-7080
14.4
78.3
0.99
4.07
1.65
C-6070
30.26
57.29
0.84
1.42
1.43
C-4060
48.0
42.6
1.26
5.38
1.54
* Presence of about 5wt.% of barite (BaSO4), as a non-wetting additive.
Others
5.12*
0.59
8.76*
1.22
samples were examined by means of optical and scanning electron microscopy. X-Ray
analyses are also performed to identify the nature of oxidation products.
C-7080
with Al-5wt.%Mg
C-4060
with Al-5.5wt.%Zn
C-6070
with 7075 alloy
Al-5wt.%
Mg
C-4060
C-6070
C-7080
C-8090
None
MgCl2
KCl
CaCl2
NaCl
MgF2
CaF2
NaF
Na3AlF6
Al-5.5wt.%
Zn
None
Na3AlF6
7075 alloy
None
Na3AlF6
: Refractory corrosion;
: Metal oxidation;
: Negligible;
: Moderate;
: Low;
: High;
: Extremely high
The above results underline the high tendency of Al-5wt.%Mg and 7075 alloys to
oxidation in the absence of fluxing agent. Moreover, among the tested alloys, Al5wt.%Mg appeared to be more aggressive against the refractory materials. Even the
refractories containing barium sulfate as a non-wetting agent (C-6070 and C-8090) were
affected by aluminum chemical attack. The fact that the non-wetting additives lose their
efficiency in protecting the refractories against Al-5wt.%Mg alloy attack after firing at
temperatures higher than 1000C, has already been discussed in the previous works (1,
4).
Based on its high tendency to oxidation and its aggressiveness against refractory
materials, the effects of fluxing agents were studied mainly with the Al-5wt.%Mg alloy.
Figure 3 and 4 show some cross sections of the samples, tested with this alloy containing
different chloride and fluoride salts, respectively. Referring to the data given in Table II,
it may be noted that the addition of salts reduced significantly the oxidation of the molten
aluminum alloys in most cases. This could be simply resulted from the reduction of the
contact surface of molten metal with air, due to the salt presence. Moreover, except the
cases involving NaF-based salts, the addition of the salts had no appreciable effect on the
corrosion of the refractory samples. However, when NaF or cryolite is used, severe
corrosion is observed in the aluminosilicate refractory samples. The aggressiveness of
these salts is likely related to the volatility of sodium and its high tendency to oxidation
and reaction with refractory oxide compound (5). To evaluate the reactivity of cryolite
with zinc as aluminum alloying element, the Bellyband tests with Al-5.5wt.%Zn and
7075 alloys were performed. Figure 5 compares the aspect of samples C-6070 with and
without Na3AlF5 in the case of zinc containing alloys. Similar to the Al-5wt.%Mg, the
addition of cryolite to aluminum-zinc alloys increased significantly the corrosion of the
four tested materials.
C-8090
With MgCl2
C-7080
With KCl
C-4060
With CaCl2
C-6070
With NaCl
C-7080
With MgF2
C-4060
With CaF2
C-8090
With NaF
C-6070
With Na3AlF6
Al-5.5wt%Zn
Without salt
Al-5.5wt%Zn
With Na3AlF6
7075 alloy
Without salt
7075 alloy
With Na3AlF6
Figure 5 - Cross Sections of the C-6070 Crucibles upon Test with Al-Zn alloys
For a given aluminum alloy, with or without salt, the oxidation aspect of molten
metal differs from a refractory crucible sample to another (see Table II). This suggests
that the chemical interaction between aluminum and aluminosilicate materials influences
the kinetics of metal oxidation. To better analyze the role of fluxing agents on the
oxidation behavior of aluminum alloys, thermogravimetric measurements were carried
out using alumina crucible, which is known as a highly resistant material against
aluminum chemical attack.
Thermogravimetric Analyses
To investigate the direct melt oxidation of Al-5wt.%Mg, with and without salts,
the weight variation of metallic samples as a function of heating process time was
continuously measured. Figure 6 shows the weight gain (dm) of an Al-Mg alloy,
expressed in mg/cm2, in the absence of salts. Based on the recorded thermogravimetric
measurements, the kinetics of metal oxidation was then calculated (in g/cm2.s). As
shown in Figure 7, the oxidation of Al-Mg alloys follows different characteristic steps
during heating process. According to the literatures first (6), an abrupt weigh gain,
represented by a narrow and sharp peak in Figure 7, is observed at around 850C. This
characteristic peak corresponds to a spinel (MgAl2O4) formation below a rapidly formed
thin external MgO layer, during heating ramp. Following the spinel formation, the
oxidation kinetics slows during a certain time, called incubation period. In the present
work, the incubation period extends from the end of the heating to the beginning of the
isothermal peak (at 1175C) and lasts about one hour (Figures 6 and 7). It is postulated
that, during this period, a slow thickening of the spinel layer, accompanied by the
development of an internal metallic network, takes place. Thus, the metal may infiltrate
through the spinel layer and reach the MgO layer. Once in contact with molten
aluminum, the magnesia layer becomes thermodynamically unstable and can be reduced
to form corundum (7). The incubation period ends with the nucleation of Al2O3 nodules,
between the spinel and magnesia layers. Several studies have shown that the incubation
time could be reduced, for instance by doping the metal surface with specific chemical
species such as silica powders (6-8). In the present investigation, a reduction of the
incubation period was observed through a complementary test using a little piece of
corundum as surface dopant. Following the incubation period, a second rapid weight
gain, characterized by the large peak in the kinetics curve of Figure 6, occurs. According
to the literatures (6, 7), this second large and extended peak corresponds to the growth of
an Al2O3/Al composite material, sandwiched between MgO and MgAl2O4 layers. It
seems that this ceramic/metal composite continues to grow, in a quasi-steady state, as
long as the molten alloy is somewhere in contact with bulk spinel; i.e., a continuous metal
supply is assumed. According to the theoretical analyses (9), the corundum growth rate in
this quasi-steady state is governed by the oxygen partial pressure and temperature, as
expressed in the following equation:
VOxidation = 3.6108 PO21/4exp-370(kJ/mol)/RT
In the present experimental conditions (PO2=0.2atm., T=1448K) , the calculated
value for the theoretical oxidation rate is 11 g/cm2.s. This value, reported in the
experimental curves, is used for comparison. The average experimental value established
from the slope of the oxidation curve in Figure 5 is 20 g/cm2.s.; almost two times higher
than the theoretical value.
1400
800
750
1200
700
650
Temperature T (C)
550
500
dm /dt
800
450
400
350
600
300
250
400
600
1000
200
150
100
200
50
0
0
-50
0
10
15
20
25
30
35
40
45
50
Time t (h)
1400
55
T
1200
50
Temperature T (C)
40
35
800
30
25
600
20
400
15
45
1000
10
5
200
0
0
-5
0
10
15
20
25
30
35
40
45
50
Time t (h)
The average oxidation rate of the Al-5wt.%Mg samples, containing different salts,
is reported in Table III. An important slowdown, about one order of magnitude, in the
oxidation kinetics of the alloy is observed especially with the addition of chlorides.
Moreover, the oxide colors of thermo-balance samples with chloride salts appear visibly
whiter compared to the others, as shown in Figure 8. In the case of MgF2 salt addition, an
extensive MgO whiskers formation above the thermo-balance alumina crucible was
observed (details in the next section). It should be noted that with this salt, the reduction
in the oxidation rate of samples was less significant, compared to the other salts.
Table III: Oxidation aspects of Al-5wt.%Mg samples during thermo-balance tests
Salt
Oxidation
rate*
(g/cm2.s)
Oxide color
Observation
None
MgCl2
KCl
CaCl2
NaCl
MgF2
CaF2
NaF
Na3AlF6
20
11
Dark gray
White
& gray
White
White
White
Dark gray
Dark gray
Dark
gray
Dark gray
NaCl was
decomposed
during
heating
Extensive
MgO
whiskers
formation
Low MgO
whiskers
formation
Metal
almost
totally
oxidized
* Average rate established in the first fifteen hours of the thermo-balance tests.
Saltfree
MgCl2
NaCl
MgF2
NaF
Na3AlF6
1400
1200
15
5
1000
Temperature T (C)
dm/dt
-5
Steady-state
800
-10
-15
600
-20
-25
400
-30
10
-35
200
NaCl decomposition
-40
-45
0
10
15
20
25
30
35
40
45
50
Time t (s)
55
T
1200
1000
Temperature T (C)
35
dm/dt
800
25
600
15
400
45
5
200
-5
0
10
15
20
25
30
35
40
45
50
Time t (h)
SEM Analyses
To better understand the difference between the effects of chlorides and fluorides
on the oxidation behavior of Al-Mg alloys, some thermo-balance samples were observed
and analyzed by a scanning electron microscope. Figure 11 illustrates the appearance of
the external oxide surfaces, i.e. in direct contact with atmosphere, of the samples
containing NaCl and CaF2. The X-Ray element analyses performed on these sample
surfaces are given in Figure 12. The sample containing NaCl seems to be covered by a
continuous MgO layer, having visibly a smooth appearance, whereas with CaF2, the
oxide surface appears more tortuous and contains a large amount of aluminum. This may
confirm the earlier suggestion concerning the periodic flow of molten aluminum from
bulk to the oxide surface and its direct exposure to the atmosphere during thermo-balance
tests of fluoride-doped samples. In other words, with fluorides, the external MgO layer is
less protective in comparison with chlorides. This may also explain why with fluorides
the corrosion of aluminosilicate samples appeared more pronounced than with chlorides.
NaCl
CaF2
NaCl
CaF2
Figure 12 - X-Ray Spectra of the Oxidized Sample Surfaces in Presence of NaCl and
CaF2
Figures 13 and 14 show the cross sectional microstructures of the samples doped
with CaCl2 and cryolite, respectively. The X-ray mapping of the three principal elements,
i.e. Al, Mg and O, constituting the oxide layers of the samples are also shown in these
figures. The overall outcomes of the oxide layers of these salt-doped samples are in good
agreement with the general observations and analyses of aluminum-magnesium alloy
oxidation. The presence of an intermediate spinel layer, in contact with metal bath, and
bulk corundum is quite visible in both cases. The thickness of the oxide layers with
Na3AlF6 (about 2mm) is 4 times larger than that with CaCl2 (about 500m). This is also
in good agreement with the above thermogravimetric analyses, showing an average
weight gain rate of about 4 times higher with fluorides in comparison with chlorides
(Table III). The main difference between the two microstructures is the presence of a
thick and relative dense MgO external layer, in the case of CaCl2 addition. The thickness
of this magnesia layer (50 to 100m) is at least one order of magnitude higher than that
(1 to 10m) usually observed during high temperature oxidation of aluminummagnesium alloys (7-9). The formation of such a thick magnesia layer may also explain
why with chloride surface doping, the kinetics of oxidation was more sluggish. This may
also suggest that the effects of salt addition are not limited only to a physical barrier role,
but it may also influence the microstructure of the oxide layers.
Finally, Figure 15 shows the micrographs of whiskers and droplets formed above
the sample with MgF2. Using X-ray analyses, these whiskers were identified as MgObased crystals, which apparently have been nucleated and grown from magnesium vapor
phase during thermo-balance test.
Magnesia
Corundum
Spinel
Aluminum
Al
Mg
Figure 13 - Microstructure and X-Ray Mapping of the Oxide Products Formed on the
Surface of an Al-5wt.%Mg Sample Doped with CaCl2.
Corundum
Spinel
Aluminum
Al
Mg
Figure 14 - Microstructure and X-Ray Mapping of the Oxide Products Formed on the
Surface of an Al-5wt.%Mg Sample Doped with Cryolite
Droplets
Whiskers
CONCLUSION
The addition of chlorides and fluorides surface dopants affects differently the
oxidation and refractory corrosion generated by aluminum alloys. From the corrosion
point of view, the use of chlorides has no significant effects, while with NaF-based salts
the metal attack could be critically accelerated. The aggressiveness of sodium fluoride
versus refractory materials were observed in both aluminum-magnesium and aluminumzinc alloys. The chlorides also appeared to be more efficient than fluorides in the
ACKNOWLEDGEMENTS
The authors are grateful to the Natural Sciences and Engineering Council of Canada for
its financial support within the research activities of the NSERC-REFRAL Chair. The
authors also acknowledge the industrial partners of this Chair, i.e., Alcan International,
Pechiney CRV, RHI Canada and Lafarge Refractories, for their financial and technical
support.
REFERENCES