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Formation of potholes in bottom linings of hall cells

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Conclusion

The mechanism of pothole formation may be summarized as follows:

  1. 1.

    Because of shrinkage during baking of green potlining, cracks form in monolithic lining or in the tamped seams of block linings.

  2. 2.

    After electrolysis starts, sodium enters the lining, causing it to expand.9 Since the lining is usually surrounded by soft insulation, lining expansion is unrestrained and cracks open up.

  3. 3.

    Bath vapors or liquid bath interacting with or condensing in the bottom insulation causes growth. Resulting upward pressures cause heaving of the lining and further opening of cracks.

  4. 4.

    Flow of the metal pad across cracks (or around obstructions) combines with the effect of magnetic flux to produce local whirlpools.

  5. 5.

    Abrasive “muck” or undissolved alumina suspended in the whirlpool scours away the coating of aluminum carbide on the carbon to produce an eroded pothole.

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References

  1. Extractive Metallurgy of Aluminum, Gary Gerard, ed., Interscience Publishers, New York (1963) 403–459.

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  2. Dell, M. B., J. Metals 19, No. 14 (March 1967).

  3. Reference 1, p. 444.

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  4. Givry, J. P., “Computer Calculation of the Magnetic Effects Within the Bath in the Aluminum Electrolytic Cell,” preprint of paper presented before AIME, Los Angeles Meeting, 1967, Example 4.

  5. Gebhardt, E., Becker, M., and Dorner, S., Zeit Metalkunde 44, 573 (1953).

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  6. Rothwell, E., J. Inst. Metals 90, 389 (1962).

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  7. Heaton, E. L., Aluminum Company of America (private communication).

  8. Dell, M. B., private communication.

  9. Dell, M. B., Reference 1, pp. 409–413.

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Authors and Affiliations

  1. Alcoa Research Laboratories, Aluminum Co. of America, New Kensington, Pa., USA

    M. B. Dell & R. W. Peterson

  2. Aluminum Co. of America, Wenatchee, Washington, USA

    J. N. Rumble

Authors
  1. M. B. Dell
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  2. R. W. Peterson
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  3. J. N. Rumble
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Dell, M.B., Peterson, R.W. & Rumble, J.N. Formation of potholes in bottom linings of hall cells. JOM 20, 55–58 (1968). https://doi.org/10.1007/BF03378746

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  • DOI: https://doi.org/10.1007/BF03378746

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