Melt refining and purification processes in Al alloys: a comprehensive study

Abstract Aluminum and its alloys having lots of advantageous properties are among the most-used metallic materials. So, it is of immense importance to find suitable processes and methods leading to high-quality purified Al melt. In this regard, there are numerous challenges in achieving high purity Al melts, such as its propensity to react with air, oxygen, and water vapor, the presence of a variety of oxide, non-oxide, and solid particle inclusions that lead to the production of pores, cracks, pinholes, and dross, finally adversely influencing the overall quality of the product. The main methods of melt refining are fluxing, floatation, and filtration, but more sophisticated methods have also emerged. The best method for purification can be chosen based on the type of impurities and the desired level of purification. With the industrial development, the need to establish more cost-effective and simpler methods has increased, and in addition, methods should be considered for recycling large volumes of scarp Al parts that contain more impurities. Moreover, achieving high purity melt is also a vital issue for use in specific applications. The present article has been written to discuss the above issues and focus on the study of various methods of aluminum purification.