Systems and methods for converting metal oxide to metal using metal carbide as an intermediate, include: reacting the metal oxide with carbon to produce the metal carbide, wherein the metal carbide is in a form of powder or pellets; and subjecting the metal carbide produced from the metal oxide and the carbon to electrolysis in an electrorefiner to produce and purify the metal.

Systems and methods for converting metal oxide to metal using metal carbide as an intermediate, include: reacting the metal oxide with carbon to produce the metal carbide, wherein the metal carbide is in a form of powder or pellets; and subjecting the metal carbide produced from the metal oxide and the carbon to electrolysis in an electrorefiner to produce and purify the metal.

A method and an apparatus for manufacturing a metallic article involve providing a non-metallic feedstock, for example in the form of an oxide of a desired metal or a mixture of oxides of the components of a desired metal alloy. A manufacturing apparatus has a reduction apparatus for electrochemically reducing the feedstock to a metallic product and a processor for converting the metallic product to a metallic powder. The powder is fed into an additive-manufacturing apparatus for fabricating the metallic article from the metallic powder. At least the reduction apparatus and the processor, and preferably also the additive-manufacturing apparatus, are collocated, or located in the same container, or in the same building, or on the same site.

A method and an apparatus for manufacturing a metallic article involve providing a non-metallic feedstock, for example in the form of an oxide of a desired metal or a mixture of oxides of the components of a desired metal alloy. A manufacturing apparatus has a reduction apparatus for electrochemically reducing the feedstock to a metallic product and a processor for converting the metallic product to a metallic powder. The powder is fed into an additive-manufacturing apparatus for fabricating the metallic article from the metallic powder. At least the reduction apparatus and the processor, and preferably also the additive-manufacturing apparatus, are collocated, or located in the same container, or in the same building, or on the same site.

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.

Provided is a method for preparing metallic titanium by anode-electrolysis of carbonized/sulfurized ilmenite, and relates to the technical field of mineral processing and electrochemical extraction of metallic titanium in molten salts in non-ferrous metallurgy. The method uses titanium-containing ore, carbon (C) and sulfur (S) as raw materials and prepares a Ti—C—S/titanium sulfide anode material with high electric conductivity through a sintering reaction, and then uses the Ti—C—S/titanium sulfide anode to prepare metallic titanium in a molten salt electrolyte system successfully. With the Ti—C—S composite soluble anode in the present invention, metallic titanium is deposited at the cathode and CS.sub.2/S.sub.2 gas is generated at the anode in the molten salt electrolysis process; in addition, the gas can be used as a raw material to effectively treat the ore to prepare titanium sulfide.

A method for producing metal titanium by carrying out electrolysis using an anode and a cathode in a molten salt bath, the method using an anode containing metal titanium as the anode, the method comprising a titanium deposition step of depositing metal titanium on the cathode, wherein, in the titanium deposition step, a temperature of the molten salt bath is from 250° C. or more and 600° C. or less, and an average current density of the cathode in a period from the start to 30 minutes later of the titanium deposition step is maintained in a range of 0.01 A/cm.sup.2 to 0.09 A/cm.sup.2.

A method of electrolytic reduction of a feedstock comprising oxygen and a first metal comprises the steps of, arranging the feedstock in contact with a cathode and a molten salt within an electrolysis cell, arranging an anode in contact with the molten salt within the electrolysis cell, the anode comprising a molten second metal and applying a potential between the anode and the cathode such that oxygen is removed from the feedstock to form a reduced feedstock. The oxygen removed from the feedstock reacts with the molten second metal to form an oxide comprising the second metal. The second metal is aluminium. The reduced feedstock may comprise a proportion of aluminium.

A method of electrolytic reduction of a feedstock comprising oxygen and a first metal comprises the steps of, arranging the feedstock in contact with a cathode and a molten salt within an electrolysis cell, arranging an anode in contact with the molten salt within the electrolysis cell, the anode comprising a molten second metal and applying a potential between the anode and the cathode such that oxygen is removed from the feedstock to form a reduced feedstock. The oxygen removed from the feedstock reacts with the molten second metal to form an oxide comprising the second metal. The second metal is aluminium. The reduced feedstock may comprise a proportion of aluminium.