Cathode for electrolytic production of titanium and other metal powders

Abstract

Disclosed herein are electrolytic cells comprising cathodes having a non-uniform current distribution and methods of use thereof.

1 . A method of controlling the morphology of a titanium-containing product in an electrolytic cell comprising the steps of:
 (a) providing an electrolytic cell comprising a molten electrolyte, a cathode having a non-uniform current distribution in contact with the molten electrolyte, and an anode in contact with the molten electrolyte;   (b) providing a titanium-containing compound to the molten electrolyte; and   (c) applying either a fixed voltage or a fixed current across the anode and the cathode thereby depositing a metal comprising titanium on the cathode.   
   
   
       2 . The method of  claim 1 , comprising during or after step (c) the further step of removing the titanium from the cathode when the metal attains a morphology suitable for powder metallurgical applications. 
   
   
       3 . The method of  claim 2 , wherein the removing step is accomplished by fluid flow, vibration, or blown gas. 
   
   
       4 . The method of  claim 2 , wherein the metal is a low aspect ratio powder with a particle size of less than 45 microns. 
   
   
       5 . The method of  claim 2 , wherein the metal is asymmetric powder particle with a particle size in a range of from 45 to 150 micron. 
   
   
       6 . The method of  claim 5 , wherein the asymmetric powder particle has an aspect ratio of greater than 1.5. 
   
   
       7 . The method of  claim 1 , wherein the cathode is wire mesh, bristles, rods, or combinations thereof. 
   
   
       8 . The method of  claim 1 , wherein the metal is titanium. 
   
   
       9 . The method of  claim 1 , wherein step (b) is accomplished by adding the titanium-containing compound to the molten electrolyte. 
   
   
       10 . The method of  claim 1 , wherein the titanium-containing compound is titanium monoxide or titanium dioxide. 
   
   
       11 . The method of  claim 1 , wherein the anode is a consumable anode and the titanium-containing compound is a component of the consumable anode which is provided to the molten electrolyte