Preparation of Al-Si Master Alloy by Electrochemical Reduction of Fly Ash in Molten Salt

An electrochemical method on preparation of Al-Si master alloy was investigated in fluoride-based molten salts of 47.7wt.%NaF-43.3wt.%AlF₃-4wt.%CaF₂ containing 5 wt.% fly ash at 1233 K. The cathodic products obtained by galvanostatic electrolysis were analyzed by means of x-ray diffraction, x-ray fluorescence, scanning electron microscopy, and energy-dispersive spectrometry. The result showed that the compositions of the products are Al, Si, and Al_3.21Si_0.47. Meanwhile, the cathodic electrochemical process was studied by cyclic voltammetry, and the results showed the reduction peak of aluminum deposition is at ?1.3 V versus the platinum quasi-reference electrode in 50.3wt.%NaF-45.7wt.%AlF₃-4wt.%CaF₂ molten salts, while the reduction peak at ?1.3 V was the co-deposition of aluminum and silicon when the fly ash was added. The silicon and iron were formed via both co-deposition and aluminothermic reduction. In the electrolysis experiments, current efficiency first increased to a maximum value of 40.7% at a current density of 0.29 A/cm², and then it decreased with the increase of current density. With the electrolysis time lasting, the content of aluminum in the alloys decreased from 76.05 wt.% to 48.29 wt.% during 5 h, while the content of silicon increased from 15.94 wt.% to 37.89 wt.%.