ICCE/9 NINTH ANNUAL INTERNATIONAL CONFERENCE ON COMPOSITE ENGINEERING

RECYCLING OF Al-MMC IN IONIC LIQUIDS AT NEAR ROOM

TEMPERATURE
Venkat Kamavaram* and Ramana G. Reddy+
*
Graduate Student +ACIPCO Professor & Associate Director
Department of Metallurgical and Materials Engineering & Center for Green Manufacturing
The University of Alabama, P.O. Box 870202 Tuscaloosa, AL 35487-0202, U.S.A

Abstract in molten Al solution. The formation of Al3C4

Recycling of aluminum metal matrix composites via
electrolysis in ionic liquids at near room temperature
was investigated. The electrolytic melt comprised 1-
butyl-3-methylimidazolium chloride (BMIC) and
anhydrous AlCl3. Impure aluminum composite
(Duralcan MMC Al-380, 20 vol% SiC) was
electrochemically dissolved at the anode and pure
aluminum (99.9%) was deposited on a copper
cathode. The extent of separation of various
components was measured by X-ray diffraction, and
mass spectrometer. The electrorefining process
yielded current density in the range of 200-500
A/m2, and current efficiency of about 90%. The
results indicated that impurities such as Si, Cu, Ni,
Fe, Mg, Mn, and SiC particles were removed as
anode residue. Energy consumption of about 3.0
kWh/kg-Al was obtained at a cell voltage of 1.0V
and cell temperature of 105C. Low energy
consumption and no pollutant emissions are the two
main advantages of this process compared with the
present industrial processes.
Results & Discussion
The common method of recycling the ceramic
particulate reinforced MMC metals is by salt fluxing
technique [1]. This process is based on the principle
of effective dewetting of the ceramic particles from
the aluminum matrix. This is done at high
temperatures normally at the melting temperature of
aluminum. The SiC particulates are
thermodynamically unstable in a high temperature
molten Al solution, and the following reaction is
feasible [2].
3Al(l) + 4SiC(S) Al3C4(S) + 4Si(l) (1)
Where Al3C4 is formed at the interface of SiC
particulate and Al alloy, as SiC crystal is dissolved
seriously degrades the molten MMCs fluidity, its
resistance to corrosion, and ultimately the
mechanical properties of the MMC casting.
In the present process the formation of Al3C4 is
completely eliminated, as the operating temperature
is well below the temperature of liquid aluminum
used in the above process. The electrolytic process
does not influence the reinforcement SiC, as the
anodic reaction Eq. (2) dissolves the aluminum
matrix only. And the dissolved aluminum by the
anodic reaction is deposited on the copper cathode,
(Fig. 1.) by the cathodic reaction Eq. (3). The cell
voltage controls the rate of the reaction, and this rate
is measured by the current density of the cathodic
reaction. The current density increases with the
increase in cell voltage as seen in Fig. 2.
Al + 7AlCl4 4Al2Cl7 + 3e (2)
4Al2Cl7 + 3e Al + 7AlCl4 (3)
The X-ray diffraction pattern of the deposited
aluminum and impure aluminum (anode) are shown
in Fig. 3 & Fig. 4. It was observed from both the
spectrometer and X-ray diffraction analysis that the
impurity content of the deposited aluminum is very
low. The SiC reinforcement and other components
were removed as anode residue or precipitated to the
bottom of the cell Fig. 5.
Conclusions
Al-MMC composite scrap is recycled using
electrolysis in ionic liquids at near room
temperatures. High purity aluminum (99.9%) is
obtained. Low energy consumption, low
temperatures and no pollutant emissions are the
advantages of the present process over the current
industrial processes.

359

July 1-6, 2002 International Community for Composite Engineering and

San Diego, CA College of Engineering, University of New Orleans
 ICCE/9 NINTH ANNUAL INTERNATIONAL CONFERENCE ON COMPOSITE ENGINEERING

3500
+ + Al
3000 Si
* SiC
2500

Intensity, cps
Copper
2000
Aluminum
1500 +

1000
+
* +
500
* + ++
*
0
20 40 60 80 100 120 140
2

Fig. (1): Micrograph of Al deposited on the cathode. Fig. (4): X-Ray diffraction pattern of the Al-MMC
anode before the electrolysis.
Average current density, A/sqm

340 100 Cathode current efficiency, %

320
80
300
280 60
260 SiC
Al alloy
240 40 SiC
220
20
200
180 0
1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9

Cell voltage ,V

Fig. (2): The effect of cell voltage on the average

current density and cathode current efficiency.

Fig. (5): Micrograph of Al-MMC anode after the

2500 electrolysis with the SiC particles seen in the
Al aluminum alloy matrix.
Relative intensity, CPS

2000
References
1500
Al [1] D.M. Schuster, M.D. Skibo, R. S. Bruski, R.
1000 Provencher and G. Riverin: The Recycling
Al Al and Reclamation of Metal-Matrix
500 Al
Composites, JOM, 45 (1993), 26-30.
[2] T. Iseki, T. Kameda and T. Maruyama:
0 Interfacial Reactions between SiC and
20 30 40 50 60 70 80 90 Aluminum during Joining, Journal of
2, degree Materials Science, 19 (1984) 1692-1698.
Fig. (3): X-Ray diffraction pattern of the Al-MMC
anode after the electrolysis.

360

July 1-6, 2002 International Community for Composite Engineering and

San Diego, CA College of Engineering, University of New Orleans