In-situ preparation of alumina-based cermet after reduction of iron oxide in red mud with aluminum dross

Aluminum dross (AD) and red mud (RM) are waste discharged from aluminum industry. AD and RM contain 5-15 wt% of hazardous aluminum nitride (AlN) and 20–50 wt% of iron oxide , respectively. In this work, alumina-based cermet was in-situ prepared from AD and RM, after reduction of iron oxide with AlN by pyrometallurgy . Cermet was consisted of metal reinforcement phase about 1 μm, alumina matrix phase and low-melting aluminosilicate binder. Mechanism of in-situ preparation was studied after exploring phase composition of the cermet powder. Iron, silicon and titanium oxide from RM was reduced into Fe 3 Si and TiN, which acted metal reinforcement phase in cermet. Reaction was consisted of two steps, Fe 2 O 3 , TiO 2 and AlN dissolving into low-melting aluminosilicate and electron transferring from AlN to Fe 2 O 3 , SiO 2 and TiO 2 . Content of Fe in ceramic phase was decreased from 6 at.% to 1 at.% after reduction reaction. Low-melting aluminosilicate acted both reaction solvent for reduction reaction, and binder for metal reinforcement phase and alumina matrix phase. More low-melting aluminosilicate was formed when temperature was increased from 1200 °C to 1400 °C, which made more metal balls be formed. The metal ball and alumina were bonded by low-melting aluminosilicate, which increased the bond strength between reinforcement phase and ceramic phase in cermet. This work achieved a total recycle of AD and RM into cermet. It was proposed a novel idea of in-situ preparing cermet, which was generating metal reinforcement phase in ceramic matrix phase.