Shaohu
Tao
*a,
Zhuang
Hao
a,
Yilin
Shao
a,
Ruiting
Ma
a,
Naixiang
Feng
b,
Pengyan
Mao
a and
Wu
Zhang
a
aSchool of Materials Science and Engineering, Shenyang Ligong University, Shenyang 110519, China. E-mail: tiger334421@126.com
bSchool of Metallurgy, Northeastern University, Shenyang 110819, China
First published on 23rd September 2025
Selective and efficient electrochemical analytical methods for examining the deposition of metallic aluminum are significant and necessary. Herein, the electrochemical behaviour of aluminium was studied at an inert tungsten electrode in an Na3AlF6–Al2O3–LiF–KF eutectic melt at 1253 K by means of transient electrochemical techniques. Electrochemical measurements are based on the potentiodynamic steady-state polarization curve plotting, continuous potential pulse method, constant potential method, constant current method and open-circuit chronopotentiometry. The cathodic overpotential for the deposition of metallic aluminum first decreased and then increased, while the activity of aluminum gradually decreased, as the cryolite ratio increased. Na+ ions discharged and precipitated when the cryolite ratio exceeded 3.0. KF played a decisive role in modifying electrode reactions, whereas the effect of LiF was not significant in the Na3AlF6–Al2O3–LiF–KF melt. The addition of KF not only influenced the current efficiency, but also affected the purity of the metallic aluminum, and the simultaneous addition of KF and LiF increased the dissolution loss of aluminum.
Tie et al.19 utilized cyclic voltammetry and potential step testing methods to investigate the role of aluminum–tungsten alloying during the electrolysis process. The study elaborated the alloying effect of metallic aluminum on the electrode substrate in a cryolite–alumina melt, concluding that the rate of aluminum loss increased with a rise in electrode surface activity. Raj, as well as Sum and Skyllas-Kazacos, employed cyclic voltammetry and chronopotentiometry to examine the current efficiency during aluminum electrolysis on a titanium diboride electrode and the dissolution loss of metallic aluminum, alongside the formation mechanism of aluminum–tungsten alloys on a tungsten wire working electrode and the reaction process of aluminum ions.20–23 The reaction mechanism of aluminum ions was also elucidated. In subsequent studies, cyclic voltammetry, reverse current chronopotentiometry with delay time, and chronopotentiometry were utilized to investigate the effects of temperature, alumina concentration, and anode bubbles on the dissolution loss of metallic aluminum in cryolite–alumina molten salt during the electrolysis process. Tellenbach and Landolt employed electrochemical methods such as cyclic voltammetry and sequential potential pulse experiments to study current efficiency. Thonstad and Rolseth utilized a galvanostatic method, sequential potential pulse technique, and electrochemical impedance spectroscopy to investigate and discuss the formation mechanism of cathode overvoltage.24,25 The analysis concluded that cathode overvoltage is primarily caused by diffusion overvoltage, with charge transfer overvoltage having a little effect. In subsequent research, steady-state overvoltage measurements, electrode short-circuiting, and electromotive force measurement methods were applied to study the relationship between cathode overvoltage and the cryolite ratio. Kisza and Kazmierczak investigated the effects of CaF2 and AlF3 additives on the reaction mechanism and kinetics of an aluminum cathode through AC impedance and galvanostatic relaxation methods using liquid aluminum as the working electrode.26
While these studies have laid a solid foundation for fundamental theoretical research on aluminum electrolysis,27–30 there has been relatively limited research on the influence of LiF and KF on the electrode process, and available electrochemical data in this area are scarce. The influence of LiF and KF on the cathode process during the electrolysis of aluminum in the Na3AlF6–Al2O3 molten salt system has been studied and discussed in detail.31–34 However, LiF and KF do not exist alone in the actual industrial electrolyte—both forms are present. Therefore, it is necessary to discuss the influence of the coexistence of LiF and KF on the electrolytic cathode processes occurring in the Na3AlF6–Al2O3 molten salt.
In this paper, the influence of cryolite ratios on the cathodic electrolysis process in the Na3AlF6–Al2O3–LiF–KF molten salt system was studied. Electrochemical measurements such as potentiodynamic steady-state polarization curve determination, combined with continuous potential pulse, constant potential, constant current and open-circuit chronopotentiometry methods were used to study the electrochemical reaction processes in the electrolyte melt.
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| Fig. 2 Potentiodynamic cathodic polarization curves of Na3AlF6–Al2O3–LiF–KF at the tungsten electrode as a function of cryolite ratio. | ||
As can be observed from Fig. 2, the curves were divided into three feature regions. As the cryolite ratio changed, the biggest difference in the curve was observed in region B. According to the analysis, region B involves the deposition of metallic aluminum. When the cryolite ratio was between 1.5 and 3.0, the metallic aluminum began to deposit at an electrode potential of −0.7 V, and then entered the steady-state diffusion region, reaching the limit current density of metallic aluminum. Here, the electrode process was completely controlled by the diffusion process.
When the cryolite ratio was increased to between 3.5 and 4.0, the curves in region B did not reach the limit current density of metallic aluminum deposition showing a straight line with a lower slope, which changed from diffusion process control to electrochemical process control, and the conductivity of molten salt was enhanced. It can be inferred that the addition of LiF and KF increased the transfer rate of aluminum-containing complex ions when the cryolite ratio was between 1.5 and 3.0. With the increase in the cryolite ratio, the initial potential of the linear region C shifted positively, indicating that the cathode overvoltage of the sodium metal reaction decreased. The slope of the characteristic line presented by linear region C increased first and then decreased with the increase in cryolite ratio, indicating that the conductivity of the molten salt first increased and then decreased. The characteristic curves of the reduction of lithium and potassium metals were not detected on the potentiodynamic steady-state polarization curves.
The comparative analysis indicated that in the Na3AlF6–Al2O3–LiF–KF melt, KF played a decisive role in the electrode reaction, while the role of LiF was not obvious.31,33 With the increase in the cryolite ratio, the initial deposition potential of aluminum metal moved first negatively and then positively, which proved that the cathode overvoltage decreased first and then increased with the increase in the cryolite ratio in the Na3AlF6–Al2O3–LiF–KF melt.
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| Fig. 3 Recurrent potential double pulses of Na3AlF6–Al2O3–LiF–KF at the tungsten electrode as a function of the cryolite ratio. | ||
As seen from Fig. 3, a potential step was set at a scanning time of 5 s, and the cathodic reduction mainly occurred before the potential step at 5 s corresponding to the reduction reaction of the anions in the melt on the tungsten wire electrode. Combined with the oxidation part, it can be inferred that the reduction of the anions was mainly the reduction reaction of Al3+ ions. After the step at 5 s, the working electrode was converted to an anode reaction corresponding to the oxidation of the cathode product. Continuous potential pulse curve measurements are used to calculate the reaction electricity required by the cathodic reduction and the anodic oxidation by integrationto evaluate the dissolution loss of metallic aluminum in the process of aluminum electrolysis. Combined with the measurement of steady-state polarization curves discussed in the previous section, the cathode potential deposition in aluminum electrolysis was examined. The potential range selected for the anode was −0.8 to −0.6 V. In this potential range, oxidation of the tungsten electrode on the anode can be avoided, and the anode dissolution of the working electrode can be fully recorded. At the end of the anode reaction, the current density eventually approached zero, indicating that the product generated on the cathode was completely oxidized. When the electrolyte melt contained both LiF and KF, no obvious current plateau was observed during electrode oxidation.
Through the above analysis and integration calculation from Fig. 3, the values of Qc and Qa can be calculated (where Qc is the cathodic reduction reaction charge, Qa is the anode oxidation reaction charge). The specific values are listed in Table 1, and the trends of the Qa/Qc ratios are shown in Fig. 4. The dissolution loss data of metallic aluminum at different cryolite ratios in Na3AlF6–Al2O3–LiF–KF molten melt is shown in Table 1. The reduced cathode products are completely reacted during the whole oxidation process shown in Fig. 4. In addition, it can be concluded from the data analysis that when the cryolite ratio was between 1.5 and 2.5, the Qa/Qc ratio was basically unchanged. When the cryolite ratio was greater than 2.5, the Qa/Qc ratio decreased slightly. However, the dissolution loss of aluminum in the Na3AlF6–Al2O3–LiF–KF melt was more serious than that in Na3AlF6–Al2O3–LiF and Na3AlF6–Al2O3–KF melts based on analysis of the ratio of Qa/Qc.31–34
| Cryolite ratio | Anode oxidation potential (V) | Reduction charge (Qc) | Oxidation charge (Qa) | Q a/Qc (%) |
|---|---|---|---|---|
| 1.5 | -0.6 | 1.246 | 0.712 | 57.14 |
| −0.7 | 1.270 | 0.519 | 40.87 | |
| −0.8 | 1.283 | 0.536 | 41.78 | |
| 2.0 | −0.6 | 1.056 | 0.598 | 56.62 |
| −0.7 | 1.064 | 0.430 | 40.41 | |
| −0.8 | 0.982 | 0.317 | 32.28 | |
| 2.5 | −0.6 | 1.321 | 0.757 | 57.30 |
| −0.7 | 1.404 | 0.550 | 39.17 | |
| −0.8 | 1.285 | 0.404 | 31.44 | |
| 3.0 | −0.6 | 1.710 | 1.000 | 58.48 |
| −0.7 | 1.700 | 0.620 | 36.47 | |
| −0.8 | 1.696 | 0.475 | 28.01 | |
| 3.5 | −0.6 | 1.803 | 0.969 | 53.74 |
| −0.7 | 1.814 | 0.367 | 20.23 | |
| −0.8 | 1.743 | 0.322 | 10.40 | |
| 4.0 | −0.6 | 1.751 | 0.793 | 45.29 |
| −0.7 | 1.800 | 0.194 | 10.78 | |
| −0.8 | 1.730 | 0.180 | 18.47 |
The rate at which aluminum dissolved into the electrolyte can be expressed by the formula (2.1):
![]() | (2.1) |
In formula (2.1), NM is the dissolution loss of metallic aluminum, and DM is the diffusion coefficient of metallic aluminum dissolution; Cs and Cb represent the concentration of metallic aluminum on the electrode surface and into the molten salt, respectively; δ is the thickness of the diffusion layer, which determines the natural convection on the electrode surface, Cb = 0 is use in this experiment,
The loss current density (iloss = 3FNM) was a part of the cathode current density, representing the loss amount of metallic aluminum that was incorporated into the molten salt. The corresponding loss in electricity Qloss can be expressed as: Qloss = ∫ilossdt.
In the electrolysis process, the total amount of reduction electricity required for the deposition of metallic aluminum is Qc, as follows:
| Qc = Qdep + Qloss,c | (2.2) |
In eqn (2.2), Qdep represents the actual amount of reduction electricity required to reduce metallic aluminum on the cathode within time tc;
, represents the electricity required for the loss of metallic aluminum during cathodic deposition. The current efficiency can be expressed by θc, as follows:
![]() | (2.3) |
The oxidation energy required during the anode oxidation process is represented by Qa. The anode oxidation of metallic aluminum was only an electrochemical reaction process at this point under a given potential, while the physical dissolution of metallic aluminum occurred throughout the entire anode oxidation process. The corresponding anode oxidation current density was iloss,a.
![]() | (2.4) |
The anode oxidation energy can be expressed as:
| Qa = Qdep − Qloss,a | (2.5) |
Combining eqn (2.3) and (2.5), eqn (2.6) can be obtained:
![]() | (2.6) |
From the eqn (2.6), Qloss,a can approximately be eliminated in eqn (2.6) for Qloss,a ≈ iloss,ata, Qa ≈ iata, and eqn (2.7) can be obtained:
![]() | (2.7) |
If ia ≫ iloss,a in the equation, then
.
It was shown that the dissolution of aluminum metal included chemical dissolution, electrochemical dissolution and physical dissolution, all of which can affect the dissolution loss of aluminum metal. Through the above analysis, it can be concluded that chemical, electrochemical, and physical dissolution of metallic aluminum occurred simultaneously during the process of aluminum electrolysis. In this paper, the chemical and physical dissolution was accompanied by the reduction of metallic aluminum, while only physical dissolution occurred during the oxidation process.
According to the physical dissolution model of aluminum metal, the dissolution rate of metallic aluminum did not depend on a given electrode potential, and the same applies to cathode deposition and anode oxidation. Therefore, iloss,c = iloss,a = iloss can be obtained, and iloss,c may vary with the thickness of the diffusion layer under specific experimental conditions.
The molten salt contained a certain concentration of metallic aluminum in the industrial electrolyte, which included physical dissolution and the reaction between metallic aluminum and CO2 (secondary reaction of metallic aluminum dissolution). According to eqn (2.1), the dissolution rate of aluminum metal is directly proportional to Cs − Cb. However, the concentration of aluminum metal in the molten salt was zero, which means that Cb = 0. Therefore, the dissolution rate of aluminum metal will be higher under laboratory conditions. It can also be inferred from eqn (2.1) that the increase in the natural convection rate will also increase the dissolution loss of metallic aluminum and reduce its current efficiency.
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| Fig. 5 Chronoamperometry curves for 2 h at the tungsten electrode in Na3AlF6–Al2O3–LiF–KF as a function of the cryolite ratio. | ||
In the initial stage of electrolysis, the current density decreased significantly. When the cryolite ratio was less than 3.5 after the current attenuation. The curves tended to remain in a constant current range, and the electrode was in a stable diffusion state. However, when the molecular ratio was greater than 3.5, the current density did not level off after the attenuation, but began to linearly increase with time before finally reaching a stable state. Changes in the cryolite ratio led to different reactions on the electrode surface. When the cryolite ratio was in the range of 1.5–3.0, only the deposition reaction of metallic aluminum was observed on the electrode. However, when the cryolite ratio was increased to 3.5, other ion deposition reduction reactions occurred on the electrode surface, mainly the Na+ ion discharge reaction.
The joint intervention of Li+ and K+ ions in the molten melt can inhibit the discharge of Na+ ions and weaken the current conduction ability of Na+ ions; thus, the cathode overvoltage was reduced before the discharge of Na+ ions. Moreover, the Na+ ion content in the molten salt became higher with increasing cryolite ratio, and the Na+ ions began to discharge, resulting in a larger Na+ ion concentration gradient between the electrode surface and the electrolyte molten salt, which increased the cathode overvoltage. At the same time, the increase in the cryolite ratio led to an enhancement of the double-layer charging effect, a reduction in the electrochemical reaction rate and diffusion process to varying degrees, and an increase in the cathode overvoltage.
From the results of the measured chronopotentiometry curve (Fig. 6), it can be inferred that when LiF and KF coexist in the electrolyte molten melt, the initial deposition current of metallic sodium decreased with increasing cryolite ratio, as a result of the joint action of LiF and KF.
During the open-circuit potential scanning process, the potential decreased over time. As shown in Fig. 7, three potential plateaus (1, 2, 3) are observed, which correspond to the spontaneous physical dissolution of cathodic products on the polarized electrode.
Plateau 1 corresponds to the spontaneous dissolution of metallic aluminum, while plateau 2 corresponds to the spontaneous dissolution of the Al–W intermetallic compound. The trend of the open-circuit potential change with increasing cryolite ratio in the Na3AlF6–Al2O3–LiF–KF molten salt system was consistent with that observed in the Na3AlF6–Al2O3–LiF and Na3AlF6–Al2O3–KF molten salt systems.31–34 The duration of plateaus 1 and 2 decreased as the cryolite ratio increased. In other words, the total duration of plateaus 1 and 2 also decreased with an increase in the cryolite ratio.
Therefore, the thickness of the cathodic products became progressively thinner, and the open-circuit potentials of plateaus 1 and 2 gradually shifted positively as the cryolite ratio increased, which indicated a gradual decrease in the activity of the metallic aluminum. Plateau 3 represented an open-circuit potential state where the substances on the electrode surface had completely spontaneously dissolved, and the tungsten wire electrode had returned to its pre-polarization state.
It was found that a stratification phenomenon appeared on the tungsten wire electrode (Fig. 8), and the electrode can be roughly divided into four layers. The first layer was the metal tungsten layer, the second was the aluminum–tungsten intermetallic compound, the third layer was metallic aluminum, and the fourth layer was the electrolyte attached to the electrode. Through the SEM analysis, it was observed that the thickness of the Al–W intermetallic compound remained essentially unchanged as the cryolite ratio increased. However, when the cryolite ratio exceeded 3.5, the thickness of the Al–W intermetallic compound decreased significantly, which indicated that the simultaneous addition of LiF and KF to the melt can slow the diffusion rate of Al3+ ions, reduce the activity of Al3+ ions on the tungsten wire substrate surface, and decrease the physical dissolution of metallic aluminum. Additionally, the aluminum metal layer became gradually thinner, and the density of the aluminum metal was significantly affected, becoming increasingly porous as the cryolite ratio increased. Analysis of the elemental distribution on the surface of the working electrode showed that although oxygen was present in the aluminum metal layer, no sodium was detected, which suggested that aluminum oxyfluoride complex ions accumulated on the surface of the working electrode during the electrolysis process. While the fluorine element escaped from the electrode surface, the remaining components remained on the surface. However, it cannot be conclusively determined whether oxygen existed in the form of aluminum–oxygen complex ions. The presence of oxygen may also be attributed to the oxidation of metallic aluminum on the electrode surface, or it could be due to an increase in the cryolite ratio, which affected the discharge of Al3+ ions. As a result, some oxygen ions may not be released in time and instead adhere to the electrode surface.
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