Composition for making wettable cathode in aluminum smelting

Abstract

Compositions for making wettable cathodes to be used in aluminum electrolysis cells are disclosed. The compositions generally include titanium diboride (TiB 2 ) and metal additives, The amount of selected metal additives may result in production of electrodes having a tailored density and/or porosity, The electrodes may be durable and used in aluminum electrolysis cells.

What is claimed is: 
     
         1 . A component, comprising:
 0.01 to less than 0.5 wt. % metal additives, the balance being TiB 2  and unavoidable impurities, wherein the unavoidable impurities make up less than  2  wt. % of the component;   wherein the component has a density of at least about 85% to not greater than 99% of its theoretical density.   
     
     
         2 . The component of  claim 1 , further wherein the component comprises a geometry selected from the group consisting of: a tube, a plate, a rod. 
     
     
         3 . The component of  claim 1 , further comprising an electrode for use in an aluminum electrolysis cell. 
     
     
         4 . An electrode for use in an aluminum electrolysis cell, the electrode comprising:
 0.01 to less than 0.5 wt. % metal additives, the balance being TiB 2  and unavoidable impurities, wherein the unavoidable impurities make up less than 2 wt. % of the electrode;   wherein the electrode has a density of at least about 85% to not greater than 99% of its theoretical density.   
     
     
         5 . An aluminum electrolysis cell comprising the electrode of  claim 4 . 
     
     
         6 . A method comprising:
 producing a TiB 2  component from a TiB 2  composition, the TiB 2  composition comprising: 0.01 to less than 0.5 wt. % metal additives, the balance being TiB 2  and unavoidable impurities, wherein the unavoidable impurities make up less than 2 wt. % of the electrode,   wherein the TiB 2  component has a density of at least about 85% to not greater than 99% of its theoretical density.   
     
     
         7 . The method of  claim 6 , wherein the producing step further comprises:
 (a) pressing the TiB 2  composition; and   (b) sintering the pressed TiB 2  composition to yield the TiB 2  component.   
     
     
         8 . The method of  claim 6 , wherein the method comprises forming the TiB 2  component, the component comprising a geometry selected from the group consisting of: a plate, a rod, and a tube. 
     
     
         9 . The method of  claim 6 , wherein the producing step further comprises:
 pressureless sintering the TiB 2  composition to yield the TiB 2  component.   
     
     
         10 . The method of  claim 6 , wherein the producing step further comprises:
 sintering the TiB 2  composition at a temperature of between about 1400° C. to about 2100° C.   
     
     
         11 . The method of  claim 10 , wherein the producing step further comprises:
 pressing the TiB 2  composition at a pressure from about 70 kg/cm 3  to at least 350 kg/cm 3 .