This invention discloses a method for preparing high-purity rare-earth
ferrosilicon alloys, belonging to the field of pyrometallurgical technology. Addressing the stringent purity requirements (
oxygen content ≤50ppm,
sulfur content ≤100ppm) for rare-earth
ferrosilicon alloys in high-end manufacturing, and the technical challenges of deep removal of impurities and poor compositional uniformity in existing preparation processes, this invention provides a method for preparing high-purity rare-earth
ferrosilicon alloys integrating "deep
raw material purification - multi-stage vacuum refining -
directional solidification purification - application-oriented compositional control". The method includes: preparing an intermediate
alloy using high-purity rare-earth oxides, high-purity silica, and steel
scrap as raw materials through carbothermic reduction; placing the intermediate
alloy in a
vacuum induction melting furnace and performing multi-stage refining under a vacuum of ≤10Pa, selectively removing volatile impurities through segmented
temperature control; performing deep deoxidation and desulfurization using composite refining agent injection technology; achieving interfacial segregation separation of
impurity elements through
directional solidification technology; and finally, performing
atmosphere-protected annealing and compositional fine-tuning according to the target application field. Based on the multi-stage synergistic purification mechanism of "thermodynamic selective volatilization-kinetic spray reaction-
crystal growth interface segregation", the
rare earth ferrosilicon
alloy prepared by this invention has an
oxygen content of ≤45ppm, a
sulfur content of ≤80ppm, and a
rare earth element distribution non-uniformity of ≤±2%, which meets the application requirements of high-end fields such as
aerospace high-temperature alloys,
nuclear reactor control materials, and
semiconductor sputtering targets.