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Registered Member #8
Joined: Thu Feb 02 2006, 04:34AM
Location: Harlowton, MT, United States
Posts: 214
I am interested in the production of alloys for forging via electroreduction at 750-900°C in fused CaCl2/CaF2 of sintered mixed metal oxides (and CaCO3 or alkali metal carbonate to impart carbon). This is essentially the FFC Cambridge process.
This way a very uniform alloy is produced, similar to those made by powder metallurgy. However the raw metal is in the form of a highly porous sponge, whose voids are filled with electrolyte consisting of CaCl2, CaF2, CaO, and Ca metal. CaO as well as oxygen content in the alloy itself can be minimized if the electrolysis is carried out for an extensive time running the cell to the point of chlorine evolution, but the other electrolyte constituents still remain.
I am looking for a way to effectively leech out these materials from the spongy matrix without causing side reactions with any of the metals involved. It would be preferable to do so with the spongy material remaining in a mass so as to more easily allow forging into a dense stock, but grinding the material into a powder may also be workable. The preferred forging process is by heating the metal in fused salt so as to form a protective layer even when removed into the air for manual forging. I have just begun using this process to forge knife blades from commercial stock, but would like to extend it to spongy metals formed by oxide reduction. The issue I see with the fused salt forging is of course that the salt will tend to be absorbed by the spongy metal during heating, and so intermittent leeching stages may be needed if it is even possible.
Most of the alloys I am interested in can be obtained commercially but only with great difficulty if at all by an individual, and at very high cost. In contrast the oxides and other compounds of all the involved metals are either quite cheap to obtain in multi-kilogram quantities or only needed in small amounts. In short the price of these finished alloys is many times greater than the sum of their constituents.
The alloys I am currently most concerned with contain the following elements, which will need to remain unreactive toward whatever leeching methods will be used to clean the metal sponge.
High Speed Tool Steels containing:
Iron Carbon Chromium Vanadium Molybdenum Manganes
e Tungsten
Stellite Alloys containing:
Cobalt Chromium Carbon Nickel Iron Silicon Mangan
ese Molybdenum Tungsten
Titanium Beta Alloys containing:
Titanium Aluminum Zirconium Molybdenum Chromium T
in Iron
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Purification of Spongy Alloy
