Metal compositions and processes for fractional crystallization of a molten crude tin mixture containing lead and silver are described. A process includes separating the molten crude tin mixture into a first silver-enriched liquid drain product at the liquid end of a crystallization step and a first tin-enriched product at the crystal end of the crystallization step whereby the first silver-enriched liquid drain product comprises on a dry weight basis 6.0-30.0% wt of lead, 70.0-91% wt of tin, 95.0-99.0% wt of lead and tin together, 0.75-5.00% wt of silver, and 0.24% wt of antimony. The first silver enriched liquid drain product also includes at least one of: 0.05-0.5% wt of arsenic; 0.05-0.6% wt of copper, 0.0030-0.0500% wt of nickel, at least 0.0010-0.40% wt of bismuth, at most 1.0% wt of iron, or at least 0.0005% wt of gold, the balance being impurities.

Metal compositions and processes for fractional crystallization of a molten crude tin mixture containing lead and silver are described. A process includes separating the molten crude tin mixture into a first silver-enriched liquid drain product at the liquid end of a crystallization step and a first tin-enriched product at the crystal end of the crystallization step whereby the first silver-enriched liquid drain product comprises on a dry weight basis 6.0-30.0% wt of lead, 70.0-91% wt of tin, 95.0-99.0% wt of lead and tin together, 0.75-5.00% wt of silver, and 0.24% wt of antimony. The first silver enriched liquid drain product also includes at least one of: 0.05-0.5% wt of arsenic; 0.05-0.6% wt of copper, 0.0030-0.0500% wt of nickel, at least 0.0010-0.40% wt of bismuth, at most 1.0% wt of iron, or at least 0.0005% wt of gold, the balance being impurities.

Disclosed is an electrochemical method for high-temperature molten salt electrolysis in humid atmosphere. The method involves preparing hydrogen gas, metals/alloys, metal oxide compounds and metal hydrides in humid high-temperature molten salt environment. Hydrogen gas is generated by electrolyzing water in a molten salt electrolyte at above 100 C., and with a working cathode being a solid-state oxide pellet and a voltage applied to the electrolyzing cell being far lower than that in a direct electro-deoxidation process, the hydrogen gas generated reduces solid-state oxide cathodes to produce metals. The hydrogen ions in the molten salt can be prepared by hydrolysis reaction of the molten salt in a water vapor containing atmosphere. Corresponding metals or alloys or metal oxide compounds can be prepared by reducing iron oxide, molybdenum oxide, tantalum oxide, nickel oxide, copper oxide, titanium oxide or corresponding compound oxides and the like.

An object of the present invention is to reduce a variation in the component of a MnAl alloy deposited by a molten salt electrolysis method to thereby obtain high magnetic characteristics. In a MnAl alloy manufacturing method that electrolyzes molten salt containing a Mn compound and an Al compound to deposit a MnAl alloy, the MnAl alloy is additionally charged into the molten salt during electrolysis. According to the present invention, the concentration of the Mn compound is maintained by additional charging of the Mn compound, so that it is possible to reduce a variation in the composition of the MnAl alloy to be deposited to thereby maintain stable production conditions.

An object of the present invention is to reduce a variation in the component of a MnAl alloy deposited by a molten salt electrolysis method to thereby obtain high magnetic characteristics. In a MnAl alloy manufacturing method that electrolyzes molten salt containing a Mn compound and an Al compound to deposit a MnAl alloy, the MnAl alloy is additionally charged into the molten salt during electrolysis. According to the present invention, the concentration of the Mn compound is maintained by additional charging of the Mn compound, so that it is possible to reduce a variation in the composition of the MnAl alloy to be deposited to thereby maintain stable production conditions.

Disclosed methods relate to producing an aluminum-scandium (AlSc) alloy. A method can include providing an electrolyte bath comprising a first portion of at least one of ScF.sub.3 or AlF.sub.3 and a first portion of at least one of LiF, NaF, or KF; providing a cathode in electrical contact with the electrolyte bath; providing an anode in electrical contact with the electrolyte bath; adding a first portion of SC.sub.2O.sub.3 into the electrolyte bath; reacting an aluminum ion with the cathode; applying an electric current to the cathode, thereby reacting a scandium ion with the cathode to produce the AlSc alloy.

Disclosed methods relate to producing an aluminum-scandium (AlSc) alloy. A method can include providing an electrolyte bath comprising a first portion of at least one of ScF.sub.3 or AlF.sub.3 and a first portion of at least one of LiF, NaF, or KF; providing a cathode in electrical contact with the electrolyte bath; providing an anode in electrical contact with the electrolyte bath; adding a first portion of SC.sub.2O.sub.3 into the electrolyte bath; reacting an aluminum ion with the cathode; applying an electric current to the cathode, thereby reacting a scandium ion with the cathode to produce the AlSc alloy.

A process is disclosed for the electro-refinement of titanium aluminides to produce titanium-aluminum master alloys which process is effective even in the presence of substantial amounts of aluminum and in the presence of ten (10) or more weight percent oxygen in the material(s) to be refined. The process is likewise effective without the addition of titanium chlorides or other forms of soluble titanium to the electrolyte bath comprising halide salts of alkali metals or alkali-earth metals or a combination thereof.

A process is disclosed for the electro-refinement of titanium aluminides to produce titanium-aluminum master alloys which process is effective even in the presence of substantial amounts of aluminum and in the presence of ten (10) or more weight percent oxygen in the material(s) to be refined. The process is likewise effective without the addition of titanium chlorides or other forms of soluble titanium to the electrolyte bath comprising halide salts of alkali metals or alkali-earth metals or a combination thereof.

A method of forming an alloy includes disposing a first metal oxide and a second metal oxide in a molten salt. The molten salt is in contact with a working electrode and a counter electrode. An electrical potential is applied between the counter electrode and the working electrode to co-reduce the first metal oxide and the second metal oxide to form a first metal and a second metal, respectively.