Process for manufacture of refractory hard metal containing plates for aluminum cell cathodes
AssigneeCommonwealth Aluminum Corporation
InventorWilliam M. Buchta
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Abstract
This invention relates to a method for the preparation of improved tiles or plates of enhanced density, freedom from defects, chemical and mechanical resistance, and increased longevity in service, for use as aluminum-wettable cathode surfaces for aluminum reduction cells. A mixture of Refractory Hard Material, carbonaceous filler, carbonaceous additive, and thermosetting binder system is subjected to vacuum during mixing so as to achieve a specified penetration depth as measured by ASTM standard C 360-63. The mixed composition is then molded, cured, and baked to form elements of the desired configuration.
Claims30
A method for producing an aluminum-wettable element which comprises:
- (a) preparing a homogeneous molding composition of Refractory Hard Material, carbonaceous filler, carbonaceous additive, and thermosetting binder system, said binder system having a char yield of greater than 25 percent, wherein said filler comprises carbonaceous material smaller than 100 mesh and said additive comprises carbonaceous material selected from the group consisting of carbon particles having a size of greater than 100 mesh, and carbon fibers, and mixtures thereof;
- (b) vacuum-mixing said composition for at least 5 minutes to achieve a penetration depth of from about 25 mm to about 50 mm;
- and
- (c) molding and heating said composition to form a monolithic element comprising Refractory Hard Material in a high density carbonaceous matrix bonded by amorphous carbon.
A method for producing an aluminum-wettable aluminum reduction cell cathode surface which comprises;
- (a) preparing a homogeneous molding composition of Refractory Hard Material, carbonaceous filler, carbonaceous additive, and thermosetting binder system, said binder system having a char yield of greater than 25 percent, wherein said filler comprises carbonaceous material smaller than 100 mesh and said additive comprises carbonaceous material selected from the group consisting of carbon particles having a size greater than 100 mesh, and carbon fibers, and mixtures thereof;
- (b) mixing said composition under vacuum for at least five minutes to achieve a penetration depth in said composition from about 25 mm to about 50 mm;
- (c) molding and heating said composition to form a monolithic element comprising Refractory Hard Material in a high density carbonaceous matrix bonded by amorphous carbon;
- and
- (d) adhering said element to a cathode substrate.
Dependencies are inferred from the claim text.