Current Research Progress on the Purification of Aluminum Alloy Melts

HUANG Tao; TANG Tao; ZHENG Kaihong; ZUO Zhongqiang; WANG Hongzhen; PENG Jian

doi:10.3969/j.issn.1674-6457.2026.08.013

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Journal of Netshape Forming Engineering ›› 2026, Vol. 18 ›› Issue (8) : 145-156. DOI: 10.3969/j.issn.1674-6457.2026.08.013

Light Alloy Forming

Current Research Progress on the Purification of Aluminum Alloy Melts

HUANG Tao¹, TANG Tao¹, ZHENG Kaihong², ZUO Zhongqiang³, WANG Hongzhen³, PENG Jian^1,*

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Abstract

Aluminum alloy ingots are susceptible to defects such as porosity and non-metallic inclusions during melting and casting because of inadequate melt cleanliness, which severely degrades the mechanical properties, fatigue life, and service reliability of aluminum alloy components. With the rapid development of high-performance aluminum alloys and increasingly stringent service requirements, the development of efficient melt purification technologies for producing high-quality ingots has become a critical challenge in aluminum melting and casting. The work aims to systematically review recent research progress and emerging trends in aluminum alloy melt purification technologies. Based on their dominant purification mechanisms, existing melt purification methods can be classified into two fundamental routes: adsorptive and non-adsorptive purification. Adsorptive purification primarily involves bubble flotation, flux refining, and filtration, where external interfaces are introduced to adsorb and remove dissolved hydrogen and non-metallic inclusions from the melt. In contrast, non-adsorptive purification employs external physical fields, such as vacuum, ultrasonic, and electromagnetic fields, to modify the thermodynamic and kinetic conditions of the melt, thereby promoting hydrogen precipitation as well as the aggregation and migration of inclusions. To overcome the limitations of single purification methods in purification efficiency, treatment scale, and process stability, integrated purification technologies based on the synergistic coupling of multiple processes or physical fields have been developed, offering effective routes for deep purification of aluminum alloy melts. Through comparative analysis of the principles, purification performance, and engineering applicability of different technologies, a single purification method can hardly meet the engineering requirements of high efficiency, continuity and stability simultaneously. Future research is expected to focus on intelligent integrated purification systems with multi-process coupling, novel purification media and equipment development, and the deep integration of online monitoring, intelligent control, and digital simulation to meet the stringent cleanliness requirements of high-end aluminum alloys for melt purification.

Key words

aluminum alloys / melt purification / adsorptive purification / non-adsorptive purification / integrated purification technology / multi-process coupling

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HUANG Tao, TANG Tao, ZHENG Kaihong, ZUO Zhongqiang, WANG Hongzhen, PENG Jian. Current Research Progress on the Purification of Aluminum Alloy Melts[J]. Journal of Netshape Forming Engineering. 2026, 18(8): 145-156 https://doi.org/10.3969/j.issn.1674-6457.2026.08.013

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Funding

Key Research and Development Project of the Xinjiang Uygur Autonomous Region (2022B01028-1); Key Project of the Chongqing Technology Innovation and Application Development Special Project (CSTB2023TIAD-KPX0016, CSTB2024TIADKPX0002)