Direct preparation of Al-base alloys from their oxides/metal precursors in the eutectic LiCl–KCl melt

•Al–Cu–Li alloy was prepared using electrochemical deoxidation of Al–Cu–Li2O precursor in eutectic KCl–LiCl melt at 648 K.•Al–Nd alloy was successfully produced by the same method at 773 K.•CaCl2–LiCl melt is not a good choice for preparing Al–Li alloy because of formation of calcium aluminate.

A study was carried out on the preparation of Al–Cu–Li alloy from their oxides/metal precursors using the method of electro-deoxidation in the eutectic LiCl–KCl melt at 648 K. Cyclic voltammetry was used to characterize the system. The samples were prepared by potentiostatic electrolysis at −1.0 V to −2.0 V (vs. Ag+/Ag) for 5 h. XRD analysis shows that Li2O is not electrochemically reduced to Li at −1.0 V (vs. Ag+/Ag) or more negative potential. During the preparation process of Al–Cu–Li alloy, lithium peroxide is formed as an intermediate compound. Al–Cu–Li alloy is chemically prepared through the reaction between aluminum and lithium peroxide by heating of Al–Cu–Li2O precursors in KCl–LiCl–LiF melt at 1023 K. Eelectro-deoxidation in LiCl–KCl melt can increase the lithium content in the final alloy product. Al–Mg and Al–Nd alloy were also prepared by using the same method from their mixture of aluminum and corresponding oxide, respectively. Al–Nd alloy can only be obtained at the temperature above 773 K. Al–Li alloy could not be obtained in eutectic CaCl2–LiCl melt because of formation of calcium aluminates.