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This powder production route is used to produce high purity metal powders Applications include
Iron, copper, aluminum, chromium, zinc and magnesium Niobium, tantalum and silver Titanium and palladium
Electrodeposition of the metal in spongy or powdery state Milling of the deposited metal
Electrolytic powders are in tens of microns size range, and typically have irregular, porous and dendritic shapes with poor packing characteristics
Electrodeposition of Metals
Fundamentals
Electrochemical reactions
Cathode: A+ + e = A Anode: B = B+ + e Overall: B + A+ = A + B+
Electrons (e)
Electrolyte
Electrode: Goele = - n F Eele Eele = Eoele + RT/nF ln k Overall: Go = - n F E = (EoB - EoA) + RT aB+/ aA+ E = cell potential; Eele = electrode potential; k =Equilibrium constant n=valance of ion; F = Faradays number (96495 C/ g-equivalent)
Anode
Cathode
Efficiency =
RA RA theortical
100
Technology
Electrodeposition is in essence a refining process of impure metal ingots It involves dissolution of the impure metal from the anode in an electrolyte and depositing the dissolved metal ions on the cathode. Industrial electrorefining cells use a set of 20 to 40 anodes and cathodes connected in parallel to the power supply. Cell tanks are 3-4 m long, 1m wide and 1m deep The cell voltage is low, typically between 1 and 2 volts, while the current density is quite high ranging from 300 to 4000 A/m2
Process variables
Cell current and voltage Cathode-anode gap thickness Electrolyte concentration and temperature Intensity of bath stirring
High current density Large cathode-anode gap High bath temperature Low ion concentration of the electrolyte Minimal electrolyte agitation
Particle size in the first 2 methods depends on nucleation and growth kinetics, typically in 1 m size range The powder produced by the third method has the same size of the reducing metal, and porous. This chemical processing apply to all metals including refractory and reactive metals
Solid-Solid reactions