Method and system for TiB2 products with induction mechanism

Abstract

The present application is directed to products and methods relating to a TiB2 substrate having a guiding mechanism configured to steer a TiB2 wettable material in a predetermined direction. In some embodiments, the TiB2 substrate is at least partially covered with solid aluminum metal.

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to U.S. Provisional Patent Application No. 63 / 276,892, filed November 8, 2021, entitled “Methods and Systems of TiB2 Products with Infiltrated Solid Aluminum,” which is incorporated by reference in its entirety. [Background technology]

[0002] Aluminum has traditionally been made from alumina (Al2O3) derived from bauxite ore. Conversion of alumina (Al2O3) to aluminum is typically accomplished by a smelting process in which alumina (Al2O3) is dissolved in cryolite, a flux, and then an electric current is passed through the mixture, causing carbon from a carbon anode to attach to the oxygen component of the dissolved alumina (Al2O3), yielding aluminum and carbon dioxide as by-products. Various efforts have been made to purify aluminum, including the "Hoopes process" (see U.S. Pat. No. 1,534,315), as well as the method described in commonly owned WO 2016 / 130823. Summary of the Invention

[0003] Generally, the present disclosure relates to methods and products that include titanium diboride (TiB2) substrates or structures that use guiding mechanisms to guide the TiB2 wettable material in a predetermined direction. In some embodiments, the TiB2 substrate structure can be covered with solid aluminum metal before contacting the TiB2 wettable material. When the TiB2 wettable material contacts the TiB2 substrate, the guiding mechanism guides the TiB2 wettable material in a predetermined direction. The guiding mechanism can take many shapes and sizes. In some embodiments, the guiding mechanism can be a slot, a groove, a pore, or a combination thereof. A TiB2 substrate having at least one guiding mechanism can be used in a variety of applications, including the movement of fluids within an article. In some embodiments, the TiB2 wettable material can be any metal suitable for movement through the TiB2 substrate. In some embodiments, the TiB2 wettable material is aluminum, such as an aluminum alloy, metallic aluminum, and combinations thereof.

[0004] In one aspect, the present disclosure includes an article having a TiB2 substrate with a guiding mechanism, the guiding mechanism configured to guide the TiB2 wettable material in a predetermined direction. In some embodiments, the TiB2 wettable material includes aluminum. In some embodiments, the aluminum is selected from the group consisting of aluminum alloys, metallic aluminum, and combinations thereof. In some embodiments, the surface of the TiB2 substrate is at least partially covered with solid aluminum metal. In some embodiments, the guiding mechanism is selected from the group consisting of structures, such as slots, grooves, pores, and combinations thereof, on the TiB2 substrate. In some embodiments, the TiB2 substrate has a three-dimensional geometric shape. In some embodiments, the three-dimensional geometric shape has at least one of a rectangular shape, a square shape, a triangular shape, an elliptical shape, or an oblong shape. In some embodiments, the TiB2 substrate has an asymmetric shape. In some embodiments, the TiB2 substrate is plate-like.

[0005] In some embodiments, the TiB2 substrate is configured for use in an aluminum refining cell. In some embodiments, the TiB2 substrate is configured for use in an aluminum electrolytic cell. In some embodiments, the directing mechanism directs the TiB2 wettable material by capillary action. In some embodiments, the directing mechanism comprises pores. In some embodiments, the directing mechanism includes voids in the TiB2 substrate. In some embodiments, the porosity ranges from about 1 to about 200 pores per inch (PPI). In some embodiments, the porosity is at least about 5 pores per inch (PPI), or at least about 10 pores per inch (PPI), or at least about 15 pores per inch (PPI), or at least about 20 pores per inch (PPI). In some embodiments, the porosity is about 175 pores per inch (PPI) or less, or about 150 pores per inch (PPI) or less, or about 125 pores per inch (PPI) or less, or about 100 pores per inch (PPI) or less, or about 80 pores per inch (PPI) or less, or about 60 pores per inch (PPI) or less, or about 50 pores per inch (PPI) or less.

[0006] In some embodiments, the guiding feature comprises at least one slot, which may be open or closed, and the at least one slot extends through a thickness of the TiB2 substrate. In some embodiments, the dimensions of the at least one slot are predetermined. In some embodiments, the TiB2 substrate comprises a first protrusion and a second protrusion, and the guiding feature comprises a slot defined between an inner surface of the first protrusion and an inner surface of the second protrusion. In some embodiments, the slot extends the entire length (l) of the first protrusion and the entire length (l) of the second protrusion. In some embodiments, the entire length (l) of the first protrusion and the entire length (l) of the second protrusion range from about 0.01 meters to about 1 meter. In some embodiments, the thickness (t) of the first protrusion and the thickness (t) of the second protrusion range from about 1 mm to about 20 mm. In some embodiments, the slot extends a distance (d) between the inner surface of the first protrusion and the inner surface of the second protrusion. In some embodiments, the distance (d) ranges from about 20 μm to about 20 mm. In some embodiments, the width (w) of the first protrusion and the width (w) of the second protrusion range from about 1 mm to about 20 mm.

[0007] As noted above, in some embodiments, the slots are fully closed. In some embodiments, when the slots are fully closed, the guide mechanism is a fully closed channel. In some embodiments, at least one slot is partially closed, i.e., a partially closed slot. In some embodiments, the partially closed slot comprises a closed lateral width opening. When at least one slot is partially closed, the lateral width opening of the at least one slot can be fully closed and extend continuously over a portion of the length of the slot. When at least one slot is partially closed, the lateral width opening of the at least one slot can be partially closed over the entire length of the slot. When at least one slot is partially closed, the amount of closure of the lateral width opening of the at least one slot can vary along the length of the slot.

[0008] As described above, the substrate may include at least one channel. The channel may be of any length, width, size, or shape. In some embodiments, the channel extends substantially parallel to the longitudinal axis of the substrate. In some embodiments, the channel extends at an angle to the longitudinal axis of the substrate. In some embodiments, multiple channels may be combined into a single channel. In some embodiments, a single channel may be split into multiple channels. The cross-section of the channel may be of any shape or size. In some embodiments, the cross-section is substantially constant throughout the length of the channel. In some embodiments, the cross-section is variable throughout the length of the channel. In some embodiments, the cross-section may increase and / or decrease along the length of the channel.

[0009] In some embodiments, the guiding feature comprises a structure having at least one groove. In some embodiments, the at least one groove extends partially into the TiB2 substrate. In some embodiments, the dimensions of the at least one groove are predetermined. In some embodiments, the size and / or shape of the at least one groove is predetermined. In some embodiments, the width (w) of the at least one groove is in the range of about 10 μm to about 20 mm. In some embodiments, the groove depth (gd) of the at least one groove is in the range of about 1 mm to about 10 mm. In some embodiments, the length (l) of the at least one groove is in the range of about 1 cm to about 1 m. In some embodiments, the thickness (t) of the TiB2 substrate is in the range of about 5 mm to about 30 mm. In some embodiments, the guiding feature comprises at least two grooves in the TiB2 substrate. In some embodiments, the edge-to-edge distance (d) between the at least two grooves is in the range of about 1 mm to about 20 mm.

[0010] In another aspect, the disclosure includes an article having (a) a TiB2 substrate comprising at least one inductive feature; and (b) solid aluminum metal at least partially covering a surface of the TiB2 substrate. In some embodiments, the solid aluminum metal is at least partially contained within the at least one inductive feature. In some embodiments, the TiB2 substrate comprises a structure having a surface region, a first portion of the surface region comprising at least one inductive feature, and a second portion of the surface region being devoid of inductive features. In some embodiments, the first portion of the surface region is at least partially covered by solid aluminum metal. In some embodiments, the first portion of the surface region is at least 1% covered by solid aluminum metal. In some embodiments, the second portion of the surface region is at least partially covered by solid aluminum metal. In some embodiments, the second portion of the surface region is at least 1% covered by solid aluminum metal. In some embodiments, the solid aluminum metal covering the second portion of the surface region is in the form of a film. In some embodiments, the film comprises a thickness of 1 μm to 500 μm. In some embodiments, the second portion of the surface region is devoid of solid aluminum metal.

[0011] In some embodiments, the at least one guiding feature comprises a void volume, and at least 1% of the void volume comprises solid aluminum metal. In some embodiments, the at least one guiding feature is a structure having a slot, and the solid aluminum metal is at least partially contained within the slot. In some embodiments, the at least one slot comprises a slot volume, and the solid aluminum metal occupies at least 1% of the slot volume. In some embodiments, the at least one guiding feature is a groove, and the solid aluminum metal is at least partially contained within the groove. In some embodiments, the at least one groove comprises a groove volume, and the solid aluminum metal occupies at least 1% of the groove volume. In some embodiments, the guiding feature is in or on a substrate (e.g., a TiB2 substrate or a ceramic substrate).

[0012] In another aspect, the disclosure includes an article having (a) a web of TiB2 and (b) solid aluminum metal at least partially covering a surface of the web of TiB2. In some embodiments, the web of TiB2 defines voids in the web of TiB2. In some embodiments, the solid aluminum metal comprises the voids. In some embodiments, the voids in the web of TiB2 define a pore volume of the TiB2, and the solid aluminum metal occupies at least 1% of the pore volume.

[0013] In another aspect, the present disclosure includes a method including manufacturing a TiB2 article having at least one guiding feature and guiding a TiB2 wettable material in a predetermined direction by the at least one guiding feature. In some embodiments, the manufacturing process includes forming a TiB2 article having a plurality of pores. In some embodiments, the manufacturing process includes forming a geometric feature. In some embodiments, the manufacturing process includes machining a TiB2 article or a TiB2 article precursor to form at least one guiding feature. In some embodiments, the manufacturing process includes extruding a TiB2 feedstock into a TiB2 article precursor, the TiB2 article precursor comprising at least one guiding feature. In some embodiments, the TiB2 article precursor is an unsintered TiB2 material. In some embodiments, the method includes exposing the unsintered TiB2 material to an elevated temperature, thereby forming a TiB2 article. In some embodiments, the at least one guiding feature in the TiB2 substrate may comprise a groove, a slot, a channel, or a combination thereof.

[0014] In another aspect, the present disclosure includes an aluminum refining cell or an aluminum electrolysis cell having any of the TiB2 substrates described herein. In some embodiments, at least one of the TiB2 substrates is an electrode. In some embodiments, at least one of the TiB2 substrates is an induction device configured to induce liquid aluminum metal (e.g., molten aluminum metal) in a predetermined direction when no electric current is applied.

[0015] Although the present disclosure generally refers to TiB2 substrates, other ceramic and / or cermet substrates with guiding features may be used. Any ceramic and / or cermet substrate with guiding features may be used with any wettable metal. In some embodiments, any wettable metal may be any suitable metal for transfer through the ceramic and / or cermet substrate. In some embodiments, a suitable metal may be aluminum, e.g., aluminum alloys, metallic aluminum, and combinations thereof. In some embodiments, a suitable metal may be copper, e.g., copper alloys, metallic copper, and combinations thereof. In some embodiments, the wettable material consists essentially of aluminum, magnesium, copper, and combinations thereof. In some embodiments, the wettable material is primarily aluminum. In one aspect, the present disclosure relates to an article having a ceramic or cermet substrate with a guiding feature, the guiding feature configured to guide the ceramic or cermet wettable material in a predetermined direction. In some embodiments, the substrate is a ceramic substrate. In some embodiments, the ceramic substrate is one of a TiB2 substrate, a ZrB2 substrate, or a HfB2 substrate. In some embodiments, the ceramic wettable material is aluminum, such as aluminum alloys, aluminum metal, and combinations thereof.

[0016] Although the above disclosure is made with respect to TiB2 and aluminum, the devices, systems, and methods described herein are applicable to other ceramic and / or cermet materials other than TiB2. For example, the disclosure herein is equally applicable to other metal borides (e.g., metal diborides) having metal-wetting capabilities, such as ZrB2 and HfB2, to name just two, both of which are aluminum-wetting materials.

[0017] In some embodiments, the substrate can be a carbon-based (carbonaceous) material. In some embodiments, the carbon-based material can be an inorganic carbon-based material. Suitable carbon-based materials can include, for example, amorphous and crystalline forms of carbon. In some embodiments, the carbon-based material includes graphite. In some embodiments, the substrate includes a pre-fired carbon electrode material. The carbon-based substrate can include a plating material to promote wettability of a suitable metal, for example aluminum.

[0018] In some embodiments, the substrate can be a non-carbonaceous material. A non-carbonaceous material is any material that is not carbon-based. Non-carbonaceous materials include, for example, ceramic and cermet materials. In some embodiments, the substrate can be a ceramic or a cermet.

[0019] The ceramic material includes an inorganic, non-metallic material. The inorganic, non-metallic material can include a boride, oxide, nitride, or carbide material. In some embodiments, the ceramic material includes titanium. In some embodiments, the ceramic material includes a metal boride (e.g., a metal diboride). In some embodiments, the metal diboride material includes TiB2, ZrB2, HfB2, or SrB2.

[0020] A cermet material is a material of ceramic and metallic materials. A cermet material may include a ceramic matrix bonded by a metallic binder. In some embodiments, the cermet material includes copper (Cu), nickel (Ni), chromium (Cr), tungsten (W), molybdenum (Mo), iron (Fe), cobalt (Co), or alloys or combinations thereof. In some embodiments, the cermet material includes nickel-titanium carbide or nickel-titanium diboride.

[0021] In some embodiments, the substrate comprises, consists essentially of, or consists of the described materials. In one embodiment, the substrate consists essentially of, or consists of a ceramic. In one embodiment, the substrate consists essentially of, or consists of a cermet. In one embodiment, the substrate consists essentially of, or consists of a carbon-based material.

[0022] In some embodiments, the substrate is a plating material that promotes wettability. In some embodiments, the plating material is a ceramic and / or a cermet, such as any of the ceramic or cermet materials described herein. In some embodiments, the substrate is a carbon-based material plated with a ceramic, such as TiB2. [Brief description of the drawings]

[0023] [Figure 1A] FIG. 1A illustrates one embodiment of a method for directing a TiB 2 wettable material in a predetermined direction using a directing mechanism.

[0024] [Figure 1B] FIG. 1B illustrates another embodiment of a method for directing a TiB 2 wettable material in a predetermined direction using a directing mechanism.

[0025] [Figure 2A] FIG. 2A is a perspective view of one embodiment of the product, in which a TiB2 substrate has multiple slots as guiding features.

[0026] [Figure 2B] FIG. 2B is a first side view of the embodiment shown in FIG. 2A.

[0027] [Figure 2C] FIG. 2C is an enlarged partial cross-sectional view of the embodiment shown in FIG. 2A, indicated by the dashed circle in FIG. 2A.

[0028] [Figure 3A]FIG. 3A is a front view of one embodiment of the product, in which the TiB2 substrate has slots as a guiding feature.

[0029] [Figure 3B] FIG. 3B is a cross-sectional view of the section taken along dashed line 3B shown in FIG. 3A.

[0030] [Figure 3C] FIG. 3C is a first side view of the embodiment shown in FIG. 3A.

[0031] [Figure 4A] FIG. 4A is a front view of one embodiment of the product, in which the TiB2 substrate has multiple grooves as guiding features.

[0032] [Figure 4B] FIG. 4B is a first side view of the embodiment shown in FIG. 4A.

[0033] [Figure 4C] 4C is an enlarged partial cross-sectional view of the embodiment shown in FIG. 4A, indicated by the dashed circle in FIG. 4A.

[0034] [Figure 4D] FIG. 4D is an alternative configuration of grooves for the embodiment shown in FIG. 4C.

[0035] [Figure 5A] FIG. 5A is a side view of another embodiment of an article in which a TiB2 substrate has a plurality of pores as guide features.

[0036] [Figure 5B] FIG. 5B is an enlarged view of a portion of the embodiment shown in FIG. 5A that is indicated by the dashed lines in FIG. 5A.

[0037] [Figure 6A] FIG. 6A is a perspective view of one embodiment of the product, in which a TiB2 substrate has multiple slots as guiding mechanisms and a solid aluminum metal covers the TiB2 substrate.

[0038] [Figure 6B] FIG. 6B is a first side view of a cross section taken along arrow 6B shown in FIG. 6A.

[0039] [Figure 6C] FIG. 6C is an enlarged partial cross-sectional view of the embodiment shown in FIG. 6A, indicated by the dashed circle in FIG. 6A.

[0040] [Figure 6D] FIG. 6D is a cross-sectional side view of one embodiment of the product, in which a TiB2 substrate has multiple slots as guiding mechanisms and solid aluminum metal covers the top of the TiB2 substrate.

[0041] [Figure 6E] Figure 6E is a partial cross-sectional view taken along dashed line 6E shown in Figure 6D, showing only one of the slots. The cross section is along the top of the TiB2 substrate where the solid aluminum metal is present.

[0042] [Figure 6F] Figure 6F is a partial cross-sectional view taken along dashed line 6F shown in Figure 6D, showing only one of the slots. The cross section is along the bottom of the TiB2 substrate where no solid aluminum metal is present.

[0043] [Figure 6G] FIG. 6G is a cross-sectional side view of one embodiment in which a TiB2 substrate has multiple slots as guiding mechanisms and solid aluminum metal covers the front half of the TiB2 substrate.

[0044] [Figure 6H] FIG. 6H is a partial cross-sectional view taken along dashed line 6H shown in FIG. 6G, showing only one of the slots.

[0045] [Figure 6I] FIG. 6I is a side view of one embodiment, where a TiB2 substrate has slots and solid aluminum metal within the slots as a guide mechanism.

[0046] [Figure 6J] FIG. 6J is a partial cross-sectional view taken along dashed line 6J shown in FIG. 6I, showing only one of the slots.

[0047] [Figure 6K] FIG. 6K is a front view of one embodiment in which a TiB2 substrate has multiple slots as guiding features with solid aluminum metal covering some or none of the slots.

[0048] [Figure 6L] FIG. 6L is a first side view of the embodiment shown in FIG. 6K.

[0049] [Figure 6M] FIG. 6M is a front view of one embodiment of a TiB2 substrate having a surface region having a first portion of the surface region having a plurality of slots as guiding features and a second portion of the surface region without any guiding features.

[0050] [Figure 6N] FIG. 6N is a first side view of the embodiment shown in FIG. 6M, where a second portion of the surface area is devoid of any guidance features.

[0051] [Figure 7A] FIG. 7A is a front view of one embodiment of the product, in which a TiB2 substrate has slots as guiding features and solid aluminum metal covers the TiB2 substrate.

[0052] [Figure 7B] FIG. 7B is a cross section taken along dashed line 7B shown in FIG. 7A.

[0053] [Figure 7C] FIG. 7C is a first side view of a cross section taken along line 7C shown in FIG. 7A.

[0054] [Figure 7D] FIG. 7D is a front view of one embodiment of the product, in which the TiB2 substrate has a slot as a guide mechanism and solid aluminum metal covers a portion of the slot.

[0055] [Figure 7E] FIG. 7E is a cross section taken along dashed line 7E shown in FIG. 7D.

[0056] [Figure 7F] FIG. 7F is a first side view of the embodiment shown in FIG. 7F.

[0057] [Figure 8A] FIG. 8A is a front view of one embodiment of the product, in which a TiB2 substrate has multiple grooves as guiding features and solid aluminum metal covers the TiB2 substrate.

[0058] [Figure 8B] FIG. 8B is a first side view of a cross section taken along line 8B shown in FIG. 8A.

[0059] [Figure 8C] FIG. 8C is an enlarged partial cross-sectional view of the embodiment shown in FIG. 8A, indicated by the dashed circle in FIG. 8A.

[0060] [Figure 8D] FIG. 8D is a back view of one embodiment of the product, in which the TiB2 substrate has multiple grooves as guiding features and solid aluminum metal covers the front half of the TiB2 substrate.

[0061] [Figure 8E] FIG. 8E is a first side view of the cross section taken along line 8E shown in FIG. 8D.

[0062] [Figure 8F] FIG. 8F is an enlarged partial cross-sectional view of the embodiment shown in FIG. 8D, indicated by the dashed circle in FIG. 8F.

[0063] [Figure 9] FIG. 9 is a close-up view of a portion of an embodiment having pores and solid aluminum metal, according to some embodiments.

[0064] [Figure 10] FIG. 10 is a front view of the final sintered TiB2 foam product used in the laboratory-scale tests.

[0065] [Figure 11] FIG. 11 shows a front view of four TiB2 foam samples used in the lab-scale testing, the samples having porosities of approximately 10, 20, 30, and 45 pores per inch ("PPI").

[0066] [Figure 12] FIG. 12 is a schematic cutaway side view of the three crucibles used in the laboratory-scale testing, each containing four TiB2 foam samples that were immersed (partially or fully) in molten aluminum for 48 hours.

[0067] [Figure 13A] FIG. 13A is a front view of a TiB2 foam sample from the crucible used in the lab-scale testing after being fully immersed in molten aluminum for about 48 hours.

[0068] [Figure 13B] FIG. 13B is a front view of a TiB2 foam sample from the crucible used in the lab-scale testing after being partially immersed in molten aluminum for about 48 hours. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0069] The present disclosure is further described with reference to the accompanying drawings, in which like structures are referenced with like reference numerals throughout the several views. The drawings constitute a part of this specification and include exemplary embodiments of the present disclosure, illustrating various objects and features thereof. Moreover, the drawings are not necessarily to scale, and some features may be exaggerated to show details of particular components. Moreover, any dimensions, specifications, etc. shown in the figures are for illustrative purposes and not limiting. Therefore, specific structural and functional details disclosed herein should not be interpreted as limiting, but merely as a representative basis for teaching those skilled in the art to various uses of the present disclosure.

[0070] Among these disclosed advantages and improvements, other objects and advantages of the present disclosure will become apparent from the following description taken in conjunction with the accompanying drawings. Detailed embodiments of the present disclosure are disclosed herein. However, it should be understood that the disclosed embodiments are merely exemplary of the present disclosure, which may be embodied in various forms. Moreover, each of the examples given in connection with the various embodiments of the present invention are intended to be illustrative and not limiting.

[0071] Throughout this specification and the claims, the following terms have the meanings expressly associated therewith, unless the context clearly dictates otherwise. As used herein, the phrases "in one embodiment" and "in some embodiments" may refer to the same embodiment, but do not necessarily refer to the same embodiment. Additionally, as used herein, the phrases "in another embodiment" and "in some other embodiments" may refer to different embodiments, but do not necessarily refer to different embodiments. Thus, as described below, various embodiments of the invention can be readily combined without departing from the scope or spirit of the invention.

[0072] Additionally, the term "or" as used herein is an inclusive "or" operator and is equivalent to the term "and / or" unless the context clearly dictates otherwise. The term "based on" is not exclusive and acknowledges that a term may be based on other unrecited factors unless the context clearly dictates otherwise. Additionally, throughout this specification, the meanings of "a," "an," and "the" include plural referents. "In" includes "in" and "on."

[0073] As used herein, "aluminum wettable" means that the contact angle with molten aluminum is 90 degrees or less.

[0074] As used herein, "TiB2 wettable material" means that it has a contact angle with TiB2 of 90 degrees or less.

[0075] As used herein, "slot" means a geometric feature that runs through the thickness of the TiB2 substrate.

[0076] As used herein, "groove" means a geometric feature that extends partially through, but not completely through, the thickness of the TiB2 substrate.

[0077] As used herein, "geometric feature" means a predetermined shape formed within the TiB2 substrate. Examples include slots and grooves of any shape or size.

[0078] As used herein, "TiB2 substrate" refers to a substrate made of TiB2 that can have at least one induction mechanism. Examples of TiB2 substrates include blocks, plates, rods, wires, wool, etc. made of TiB2. In one embodiment, the TiB2 substrate consists essentially of TiB2.

[0079] As used herein, "aluminum-coated TiB2 substrate" refers to a TiB2 substrate at least partially coated with aluminum metal, where the aluminum metal is metallic aluminum and / or an aluminum alloy. In one embodiment, the aluminum metal is at least partially contained within at least one inductive feature of the TiB2 substrate. In one embodiment, the aluminum metal at least partially covers an outer surface of the TiB2 substrate. In one embodiment, the aluminum metal covers at least 5% of the surface area of ​​the TiB2 substrate. In one embodiment, the aluminum metal covers at least 10% of the surface area of ​​the TiB2 substrate. In one embodiment, the aluminum metal covers at least 15% of the surface area of ​​the TiB2 substrate. In one embodiment, the aluminum metal covers at least 20% of the surface area of ​​the TiB2 substrate. In one embodiment, the aluminum metal covers at least 25% of the surface area of ​​the TiB2 substrate. In one embodiment, the aluminum metal covers at least 30% of the surface area of ​​the TiB2 substrate. In one embodiment, the aluminum metal covers at least 35% of the surface area of ​​the TiB2 substrate. In one embodiment, the aluminum metal covers at least 40% of the surface area of ​​the TiB2 substrate. In one embodiment, the aluminum metal covers at least 45% of the surface area of ​​the TiB2 substrate. In one embodiment, the aluminum metal covers at least 50% of the surface area of ​​the TiB2 substrate. In one embodiment, the aluminum metal covers at least 55% of the surface area of ​​the TiB2 substrate. In one embodiment, the aluminum metal covers at least 60% of the surface area of ​​the TiB2 substrate. In one embodiment, the aluminum metal covers at least 65% of the surface area of ​​the TiB2 substrate. In one embodiment, the aluminum metal covers at least 70% of the surface area of ​​the TiB2 substrate. In one embodiment, the aluminum metal covers at least 75% of the surface area of ​​the TiB2 substrate. In one embodiment, the aluminum metal covers at least 80% of the surface area of ​​the TiB2 substrate. In one embodiment, the aluminum metal covers at least 85% of the surface area of ​​the TiB2 substrate. In one embodiment, the aluminum metal covers at least 90% of the surface area of ​​the TiB2 substrate. In one embodiment, the aluminum metal covers at least 91% of the surface area of ​​the TiB2 substrate.In one embodiment, the aluminum metal covers at least 92% of the surface area of ​​the TiB2 substrate. In one embodiment, the aluminum metal covers at least 93% of the surface area of ​​the TiB2 substrate. In one embodiment, the aluminum metal covers at least 94% of the surface area of ​​the TiB2 substrate. In one embodiment, the aluminum metal covers at least 95% of the surface area of ​​the TiB2 substrate. In one embodiment, the aluminum metal covers at least 96% of the surface area of ​​the TiB2 substrate. In one embodiment, the aluminum metal covers at least 97% of the surface area of ​​the TiB2 substrate. In one embodiment, the aluminum metal covers at least 98% of the surface area of ​​the TiB2 substrate. In one embodiment, the aluminum metal covers at least 99% of the surface area of ​​the TiB2 substrate. In one embodiment, the aluminum metal covers at least 100% of the surface area of ​​the TiB2 substrate.

[0080] As used herein, "plating material" and the like means a film, coating, or other thin film in contact with at least a portion of an exterior surface of a substrate, regardless of how the plating material is produced on the substrate; i.e., plating includes all methods of applying a film, coating, or thin film to a substrate.

[0081] FIG. 1A illustrates one embodiment of a method 100 for directing a TiB2 wettable material in a predetermined direction using a directing mechanism. Step 102 is an optional step shown in FIG. 1A with a dashed box. Step 102 includes covering the TiB2 substrate with solid aluminum metal. Varying amounts of the TiB2 substrate can be covered with solid aluminum metal. In some embodiments, all of the TiB2 substrate can be covered. Portions of the TiB2 substrate can be covered with solid aluminum metal, while other portions of the TiB2 substrate are free of solid aluminum. The coverage of the solid aluminum metal varies depending on the application of the TiB2 substrate. Step 104 includes contacting the TiB2 substrate with the TiB2 wettable material. Step 106 includes directing the TiB2 wettable material in a desired direction.

[0082] FIG. 1B illustrates another embodiment of a method 110 for directing a TiB2 wettable material in a predetermined direction using a directing feature. The manufacturing process 112 includes manufacturing a TiB2 product having at least one directing feature. The manufacturing process 112 can include forming a TiB2 product structure having a plurality of pores. The manufacturing process 112 can include forming a geometric feature. The manufacturing process 112 can include machining a TiB2 product or a TiB2 product precursor structure to form at least one directing feature. The directing feature in or on the product or product precursor structure can be a slot, a groove, a pore, and combinations thereof. The directing feature can include a void volume. In some embodiments, at least 1% of the void volume includes solid aluminum metal. The directing feature can direct the TiB2 wettable material by capillary action.

[0083] The manufacturing step 112 includes extruding a TiB2 feedstock into a TiB2 product precursor, the TiB2 product precursor having at least one directing feature. In some embodiments, the TiB2 product precursor is an unsintered TiB2 material. The manufacturing step 112 can include exposing the unsintered TiB2 material to an elevated temperature, thereby forming a TiB2 product. The directing step 114 includes directing the TiB2 wettable material in a predetermined direction by the at least one directing feature.

[0084] 2A is a perspective view of one embodiment of an article 200 in which a TiB2 substrate 202 has a number of slots 206 as a guiding mechanism. The slots 206 are defined between the protrusions 204. The TiB2 substrate 202 also includes a base 208 and a tip 210. The slots 206 are configured to guide the TiB2 wettable material in a predetermined direction. The TiB2 wettable material can include aluminum, e.g., aluminum alloys, metallic aluminum, and combinations thereof.

[0085] Figure 2B is a first side view of the embodiment shown in Figure 2A. Figure 2B shows a side view of product 200 showing protrusion 204. Protrusion 204 has a length (l) that extends from the top of base 208 to the end of tip 210. Tip 210 can have any of a variety of shapes, including a pointed shape, a rounded curve, or a jagged edge, etc.

[0086] Figure 2C is an enlarged partial cross-sectional view of the embodiment shown in Figure 2A, indicated by the dashed circle in Figure 2A. The partial top view shows only two of the protrusions 204. Namely, Figure 2C shows a first protrusion 204A and a second protrusion 204B, which define a first slot 206A. The first slot 206A is defined by an inner surface of the first protrusion 204A and an inner surface of the second protrusion 204B.

[0087] 3A is a front view of one embodiment of an article 300 in which a TiB2 substrate 302 has a slot 306 as a guiding feature. The slot 306 is defined by a first protrusion 304A and a second protrusion 304B (collectively, protrusions 304). The TiB2 substrate 302 also includes a base 308 and a tip 310. The slot 306 is configured to guide the TiB2 wettable material in a predetermined direction. The width (w) of one of the protrusions is also shown.

[0088] Figure 3B is a cross-sectional view of a section taken along dashed line 3B shown in Figure 3A. Figure 3B shows the thickness (t) of the protrusion 304 and the distance (d) that the slot 306 extends between the inner surface of the first protrusion 304A and the inner surface of the second protrusion 304B. Figure 3C is a first side view of the embodiment (e.g., product 300) shown in Figure 3A. Figure 3C shows the length (l) of the protrusion 304.

[0089] Figures 2A-2C and 3A-3C are similar and will be described together. The embodiment of Figures 2A-2C differs from the embodiment of Figures 3A-3C in the number of protrusions 204 / 304, the number of slots 206 / 306, and the thickness (t) of the protrusions 204 / 304.

[0090] The dimensions of the slot 206 / 306 are pre-determined. In some embodiments, the slot 206A / 306 extends the entire length (l) of the first protrusion 206A / 306A and the entire length (l) of the second protrusion 206B / 306B. The entire length (l) of the first protrusion 206A / 306A and the entire length (l) of the second protrusion 204B / 304B can range from about 0.01 meters to about 1 meter. The thickness (t) of the first protrusion 204A / 304A and the thickness (t) of the second protrusion 204B / 304B can range from about 1 mm to about 20 mm. The slot 206A / 306 extends a distance (d) between the inner surface of the first protrusion 204A / 304A and the inner surface of the second protrusion 204B / 304B. In some embodiments, the distance (d) ranges from about 20 μm to about 20 mm. The width (w) of the protrusions 204 / 304 (eg, the first protrusions 204A / 304A and the second protrusions 204B / 304B) can range from about 1 mm to about 20 mm.

[0091] The protrusions 204 / 304 can differ from one another in dimensions. The protrusions 204 / 304 can differ from one another in length (l), thickness (t), and width (w). Similarly, the distance (d) of the slots 206 / 306 can differ from one another. In some embodiments, the first protrusion 204A / 304A can have a longer length (l) and a wider width (w) and a thinner thickness (t) compared to the second protrusion 204B / 304B.

[0092] The slots 206 / 306 extend through the thickness of the TiB2 substrate 202 / 302. The number of slots may vary. In some embodiments, there may be one slot, as shown in the examples of Figures 3A, 3B, and 3C. There may also be two or more slots. The number of slots may vary depending on the intended use of the TiB2 substrate 202 / 302. In the example shown in Figures 2A, 2B, and 2C, there are six slots.

[0093] The TiB2 substrate 202 / 302 may be at least partially covered with solid aluminum metal. The slots 206 / 306 are guiding features of the TiB2 substrate 202 / 302. Other guiding features may be included in the TiB2 substrate 202, such as grooves, pores, and combinations thereof.

[0094] The TiB2 substrate 202 / 302 can have any suitable structure, size, or shape depending on the application. The TiB2 substrate 202 / 302 can have a three-dimensional geometric shape. The geometric shape surface can include at least one of a rectangular shape, a square shape, a triangular shape, an elliptical shape, or an oblong shape surface, etc. The TiB2 substrate 202 / 302 can also have an asymmetric shape. The TiB2 substrate 202 / 302 can also be plate-shaped. The TiB2 substrate 202 / 302 can use the slot 206 / 306 as a guide mechanism to guide the TiB2 wettable material by capillary action.

[0095] The TiB2 substrate 202 / 302 can be used in a variety of applications. In some embodiments, the TiB2 substrate 202 / 302 can be configured for use in an aluminum refining cell or for use in an aluminum electrolysis cell. In an aluminum refining cell, the cathode is at the top of the cell, the anode is at the bottom of the cell, and the purified aluminum moves to the top of the cell. An example of an aluminum refining cell is described in commonly owned U.S. Patent Publication No. 10,407,786, filed February 11, 2016, entitled "Systems and Methods for Purifying Aluminum." In an aluminum electrolysis cell, the cathode is at the bottom of the cell, the anode is at the top of the cell, and the produced aluminum moves to the bottom of the cell. An example of an aluminum electrolysis cell is described in commonly owned U.S. Patent Publication No. 2017 / 0283968, filed March 30, 2017, entitled "Apparatuses and Systems for Vertical Electrolysis Cells."

[0096] Figure 4A is a front view of one embodiment of an article 400 in which a TiB2 substrate 402 has a number of grooves 406 as a guiding feature. Figure 4B is a first side view of the embodiment shown in Figure 4A. Figure 4C is an enlarged partial cross-sectional view of the embodiment shown in Figure 4A, indicated by the dashed circle in Figure 4A. Figure 4D is another configuration of the number of grooves of the embodiment shown in Figure 4C.

[0097] Product 400 is similar to products 200 / 300. The differences will now be described. In some embodiments, the guiding feature of product 200 / 300 is a slot 206 / 306, in contrast to the guiding feature of product 400 being at least one groove 406.

[0098] The grooves 406 extend partially into the TiB2 substrate 402. The dimensions of the grooves 406 are predetermined. In some embodiments, the size and / or shape of the grooves 406 are predetermined. The width (w) of the grooves 406 ranges from about 10 μm to about 20 mm. The groove depth (gd) of the grooves 406 ranges from about 1 mm to about 10 mm. The length (l) of the grooves 406 ranges from about 1 cm to about 1 m. The thickness (t) of the TiB2 substrate 402 ranges from about 5 mm to about 30 mm. The edge-to-edge distance (d) between the grooves 406 ranges from about 1 mm to about 20 mm.

[0099] As shown in Figure 4C, the guiding feature comprises at least two grooves 406 in the TiB2 substrate 402. Specifically, the guiding feature comprises three grooves 406. Figure 4C shows a first groove 406A, a second groove 406B, and a third groove 406C (collectively, grooves 406).

[0100] The grooves 406 can be arranged in any pattern. The grooves 406 can also have the same dimensions as each other or different dimensions from each other. The grooves 406 can also be arranged on the sides of the TiB2 substrate 402, as well as on the front and back surfaces as shown in FIG. 4C. FIG. 4D shows a first groove 406A', a second groove 406B', and a third groove 406C' (collectively, grooves 406'). FIG. 4D shows grooves 406' of different dimensions and arrangement compared to the grooves 406 in FIG. 4C. FIG. 4C shows grooves arranged in a pattern having the same dimensions as each other, where the grooves 406 are arranged in an alternating pattern between the front and back surfaces of the TiB2 substrate 402. FIG. 4D shows that the grooves 406' can have different dimensions. In some embodiments, the second groove 406B' is the largest groove where the depth of the groove extends more than halfway through the TiB2 substrate 402. The third groove 406C' is the smallest groove and extends less than halfway through the TiB2 substrate 402'.

[0101] FIG. 5A is a side view of another embodiment of the product 500, in which the TiB2 substrate 502 has a plurality of pores as a guide feature. FIG. 5B is an enlarged view of a portion of the embodiment shown in FIG. 5A, indicated by the dashed line in FIG. 5A. As shown in FIG. 5A, the TiB2 substrate is a web of TiB2, e.g., a sponge-like structure. The pores 504 are defined by the TiB2 substrate 502, the web of TiB2. The guide feature of the product 500 can be the voids in the TiB2 substrate 502. The porosity of the TiB2 substrate 502 can range from about 1 pore to about 200 pores per square inch (PPI). In some embodiments, the porosity is at least about 5 pores per inch (PPI), or at least about 10 pores per inch (PPI), or at least about 15 pores per inch (PPI), or at least about 20 pores per inch (PPI). In some embodiments, the porosity is about 175 pores per inch (PPI) or less, or about 150 pores per inch (PPI) or less, or about 125 pores per inch (PPI) or less, or about 100 pores per inch (PPI) or less, or about 80 pores per inch (PPI) or less, or about 60 pores per inch (PPI) or less, or about 50 pores per inch (PPI) or less.

[0102] The porosity of the TiB2 substrate 502 can provide any suitable porous structure. The porosity of the TiB2 substrate 502 can be an interconnected porous structure, with at least some of the pores in fluid communication with each other to facilitate the movement of the wettable material from a first location to a second location (e.g., from a first predetermined location to a second predetermined location). Thus, the interconnected porous structure can be considered an open pore structure. In some embodiments, the porosity of the TiB2 substrate 502 can provide a random porous structure. In some embodiments, the porosity of the TiB2 substrate 502 can be an oriented porous structure. In some embodiments, the porosity of the oriented porous structure of the TiB2 substrate 502 can have a porosity gradient. In some embodiments, the porosity gradient of the oriented porous structure of the TiB2 substrate 502 can vary along a three-dimensional gradient (i.e., the porosity gradient can vary along the X-axis, the Y-axis, and the Z-axis of the TiB2 substrate 502). In some embodiments, the porosity gradient of the oriented porous structure of the TiB2 substrate 502 increases or decreases toward the center of the TiB2 substrate 502. In some embodiments, the porosity gradient of the oriented porous structure of the TiB2 substrate 502 can increase and / or decrease throughout the TiB2 substrate 502. For example, the porosity gradient of the oriented porous structure of the TiB2 substrate 502 can increase, decrease, and then increase from one end of the TiB2 substrate 502 to the other end of the TiB2 substrate 502.

[0103] FIG. 6A is a perspective view of an embodiment of a product 600, in which a TiB2 substrate 602 has a number of slots 606 as a guide mechanism, and a solid aluminum metal 612 covers the TiB2 substrate 602. In FIG. 6A, a portion of the solid aluminum metal 612 is shown peripherally or transparently to reveal the surface structure of the substrate 602. The product 600 includes a protrusion 604, a base 608, and a tip 610. FIG. 6B is a first side view of a cross section taken along arrow 6B shown in FIG. 6A. FIG. 6C is an enlarged partial cross-sectional view of the embodiment shown in FIG. 6A, indicated by the dashed circle in FIG. 6A. The embodiments shown in FIGS. 2A, 2B, and 2C are the same as or similar to the embodiments of FIGS. 6A, 6B, and 6C, except for the differences described herein. In some embodiments, the structures shown in Figures 6A, 6B, and 6C include solid aluminum metal 612 covering the TiB2 substrate structure (e.g., TiB2 substrate 202) shown in Figures 2A, 2B, and 2C. Similar features in Figures 6A, 6B, and 6C as in Figures 2A, 2B, and 2C are not repeated. Figures 6A and 6B show solid aluminum metal 612 completely covering the TiB2 substrate 602. Figure 6C shows solid aluminum metal 612 completely occupying the slot 606A between the first protrusion 604A and the second protrusion 604B.

[0104] In some embodiments, the solid aluminum metal 612 at least partially covers the surface of the TiB2 substrate 602 and / or the solid aluminum metal 612 is at least partially within the slots 606. In some embodiments, the solid aluminum metal 612 covers at least 1% of the surface of the TiB2 substrate 602. In some embodiments, the solid aluminum metal 612 covers at least 5% of the surface of the TiB2 substrate 602. In some embodiments, the solid aluminum metal 612 covers at least 10% of the surface of the TiB2 substrate 602. In some embodiments, the solid aluminum metal 612 covers at least 15% of the surface of the TiB2 substrate 602. In some embodiments, the solid aluminum metal 612 covers at least 20% of the surface of the TiB2 substrate 602. In some embodiments, the solid aluminum metal 612 covers at least 25% of the surface of the TiB2 substrate 602. In some embodiments, the solid aluminum metal 612 covers at least 30% of the surface of the TiB2 substrate 602. In some embodiments, the solid aluminum metal 612 covers at least 35% of the surface of the TiB2 substrate 602. In some embodiments, the solid aluminum metal 612 covers at least 40% of the surface of the TiB2 substrate 602. In some embodiments, the solid aluminum metal 612 covers at least 45% of the surface of the TiB2 substrate 602. In some embodiments, the solid aluminum metal 612 covers at least 50% of the surface of the TiB2 substrate 602. In some embodiments, the solid aluminum metal 612 covers at least 55% of the surface of the TiB2 substrate 602. In some embodiments, the solid aluminum metal 612 covers at least 60% of the surface of the TiB2 substrate 602. In some embodiments, the solid aluminum metal 612 covers at least 65% of the surface of the TiB2 substrate 602. In some embodiments, the solid aluminum metal 612 covers at least 70% of the surface of the TiB2 substrate 602. In some embodiments, the solid aluminum metal 612 covers at least 75% of the surface of the TiB2 substrate 602. In some embodiments, the solid aluminum metal 612 covers at least 80% of the surface of the TiB2 substrate 602.In some embodiments, the solid aluminum metal 612 covers at least 85% of the surface of the TiB2 substrate 602. In some embodiments, the solid aluminum metal 612 covers at least 90% of the surface of the TiB2 substrate 602. In some embodiments, the solid aluminum metal 612 covers at least 95% of the surface of the TiB2 substrate 602. In some embodiments, the solid aluminum metal 612 covers at least 100% of the surface of the TiB2 substrate 602.

[0105] In some embodiments, the solid aluminum metal 612 is at least partially within the slot 606. In some embodiments, if the slot 606 has a slot volume, the solid aluminum metal 612 occupies at least 1% of the slot volume. In some embodiments, the solid aluminum metal 612 occupies at least 5% of the slot volume. In some embodiments, the solid aluminum metal 612 occupies at least 10% of the slot volume. In some embodiments, the solid aluminum metal 612 occupies at least 15% of the slot volume. In some embodiments, the solid aluminum metal 612 occupies at least 20% of the slot volume. In some embodiments, the solid aluminum metal 612 occupies at least 25% of the slot volume. In some embodiments, the solid aluminum metal 612 occupies at least 30% of the slot volume. In some embodiments, the solid aluminum metal 612 occupies at least 35% of the slot volume. In some embodiments, the solid aluminum metal 612 occupies at least 40% of the slot volume. In some embodiments, the solid aluminum metal 612 occupies at least 45% of the slot volume. In some embodiments, the solid aluminum metal 612 occupies at least 50% of the slot volume. In some embodiments, the solid aluminum metal 612 occupies at least 55% of the slot volume. In some embodiments, the solid aluminum metal 612 occupies at least 60% of the slot volume. In some embodiments, the solid aluminum metal 612 occupies at least 65% of the slot volume. In some embodiments, the solid aluminum metal 612 occupies at least 70% of the slot volume. In some embodiments, the solid aluminum metal 612 occupies at least 75% of the slot volume. In some embodiments, the solid aluminum metal 612 occupies at least 80% of the slot volume. In some embodiments, the solid aluminum metal 612 occupies at least 85% of the slot volume. In some embodiments, the solid aluminum metal 612 occupies at least 90% of the slot volume.In some embodiments, the solid aluminum metal 612 occupies at least 95% of the slot volume. In some embodiments, the solid aluminum metal 612 occupies at least 100% of the slot volume.

[0106] In the embodiments shown in FIGS. 6A-6N, varying amounts of solid aluminum metal 612 occupy the slots 606 and the TiB2 substrate 602.

[0107] FIG. 6D is a cross-sectional side view of an embodiment of an article 600' in which a TiB2 substrate 602' has multiple slots 606A' as guide features, and solid aluminum metal 612' covers the top of the TiB2 substrate 602'. FIG. 6E is a partial cross-sectional view taken along dashed line 6E shown in FIG. 6D, showing only one of the slots 606A'. The cross section is along the top of the TiB2 substrate 602' where the solid aluminum metal 612' is present. FIG. 6F is a partial cross-sectional view taken along dashed line 6F shown in FIG. 6D, showing only one of the slots 606A'. The cross section is along the bottom of the TiB2 substrate 602' where the solid aluminum metal 612' is not present.

[0108] FIG. 6G is a cross-sectional side view of an embodiment of a TiB2 substrate 602'' having multiple slots 606A' as a guidance mechanism and solid aluminum metal 612'' covering half or the front of the TiB2 substrate 602''. The solid aluminum metal 612'' covers the front half of the base 608'' and tip 610''. FIG. 6H is a partial cross-sectional view taken along dashed line 6H shown in FIG. 6G, showing only one slot 606A'' of the multiple slots 606A''. The solid aluminum metal 612'' covers the front half of the slot 606A''.

[0109] FIG. 6I is a side view of an embodiment of a TiB2 substrate 602''' comprising a base 608''' and a tip 610''' with multiple slots 606A'''' as a guide mechanism, and solid aluminum metal 612''' in the multiple slots 606A''''. FIG. 6J is a partial cross-sectional view taken along dashed line 6J shown in FIG. 6I, where only one slot 606A'''' of the multiple slots 606A'''' is shown. In the embodiment of FIGS. 6I and 6J, there is no solid aluminum metal 612'''' on the outer surface of the TiB2 substrate 602''''. The solid aluminum metal 612'''' completely fills the slot volume of the slot 606A''''.

[0110] FIG. 6K is a front view of one embodiment where a TiB2 substrate 602'''' has multiple slots 606A, 606B, 606B (collectively, slots 606'''') as guiding features, with solid aluminum metal 612'''' covering some or none of the slots 606. FIG. 6L is a first side view of the embodiment shown in FIG. 6K. FIG. 6K shows a TiB2 substrate 602'''' with a base 608'''' and a tip 610''''. The slots 606'''' have various lengths, thicknesses, and amounts of solid aluminum metal 612''''.

[0111] For slot 606A, the slot length does not extend to tip 610'''' of TiB2 substrate 602''''. The top of slot 606A does not include solid aluminum metal 612''''. The bottom of slot 606A includes solid aluminum metal 612''''. For slot 606B, the slot length extends from the top of base 608'''' to tip 610''''. Slot 606B does not include solid aluminum metal 612''''. Slot 606C does not start in the same place as slots 606A and 606B. The beginning of slot 606C starts further up in TiB2 substrate 602''''. Slot 606C has solid aluminum metal 612'''' at the bottom and top, but not in the center of slot 606C.

[0112] FIG. 6M is a front view of an embodiment of a TiB2 substrate 602''''' with a surface region 620''''' having a first portion 622'''''' of surface region 620'''''' having a plurality of slots 606'''''' as guiding features and a second portion 624'''''' of surface region 620'''''' without any guiding features. Protrusions 604'''''' define a plurality of slots 606''''''. FIG. 6N is a first side view of the embodiment shown in FIG. 6M with a second portion 624'''''' of surface region 620'''''' without any guiding features.

[0113] The TiB2 substrate 602'''' has a surface region 620'''''', a first portion 622'''' of the surface region 620'''''' has at least one guiding feature and a second portion 624'''''' of the surface region 620'''' has no guiding feature.

[0114] In some embodiments, first portion 622''''' of surface region 620'''''' is at least partially covered by solid aluminum metal. In some embodiments, first portion 622''''' of surface region 620'''''' is at least 1% covered by solid aluminum metal. In some embodiments, first portion 622''''' of surface region 620'''''' is at least 5% covered by solid aluminum metal. In some embodiments, first portion 622''''' of surface region 620'''''' is at least 10% covered by solid aluminum metal. In some embodiments, first portion 622''''' of surface region 620'''''' is at least 15% covered by solid aluminum metal. In some embodiments, first portion 622''''' of surface region 620'''''' is at least 20% covered by solid aluminum metal. In some embodiments, first portion 622''''' of surface region 620'''''' is at least 25% covered by solid aluminum metal. In some embodiments, first portion 622''''' of surface region 620'''''' is at least 30% covered by solid aluminum metal. In some embodiments, first portion 622''''' of surface region 620'''''' is at least 35% covered by solid aluminum metal. In some embodiments, first portion 622''''' of surface region 620'''''' is at least 40% covered by solid aluminum metal. In some embodiments, first portion 622''''' of surface region 620'''''' is at least 45% covered by solid aluminum metal. In some embodiments, first portion 622''''' of surface region 620'''''' is at least 50% covered by solid aluminum metal. In some embodiments, first portion 622''''' of surface region 620'''''' is at least 55% covered by solid aluminum metal. In some embodiments, first portion 622''''' of surface region 620'''''' is at least 60% covered by solid aluminum metal.In some embodiments, first portion 622''''' of surface region 620'''''' is at least 65% covered by solid aluminum metal. In some embodiments, first portion 622''''' of surface region 620'''''' is at least 70% covered by solid aluminum metal. In some embodiments, first portion 622''''' of surface region 620'''''' is at least 75% covered by solid aluminum metal. In some embodiments, first portion 622''''' of surface region 620'''''' is at least 80% covered by solid aluminum metal. In some embodiments, first portion 622''''' of surface region 620'''''' is at least 85% covered by solid aluminum metal. In some embodiments, first portion 622''''' of surface region 620'''''' is at least 90% covered by solid aluminum metal. In some embodiments, first portion 622''''' of surface region 620'''''' is at least 95% covered by solid aluminum metal. In some embodiments, the first portion 622'''''' of the surface area 620'''''' is at least 100% covered by solid aluminum metal.

[0115] In some embodiments, second portion 624''''' of surface region 620'''' is at least partially covered by solid aluminum metal. In some embodiments, second portion 624''''' of surface region 620'''' is at least 1% covered by solid aluminum metal. In some embodiments, second portion 624''''' of surface region 620'''' is at least 5% covered by solid aluminum metal. In some embodiments, second portion 624''''' of surface region 620'''' is at least 10% covered by solid aluminum metal. In some embodiments, second portion 624''''' of surface region 620'''' is at least 15% covered by solid aluminum metal. In some embodiments, second portion 624''''' of surface region 620'''' is at least 20% covered by solid aluminum metal. In some embodiments, second portion 624''''' of surface region 620'''' is at least 25% covered by solid aluminum metal. In some embodiments, second portion 624''''' of surface region 620'''' is at least 30% covered by solid aluminum metal. In some embodiments, second portion 624''''' of surface region 620'''' is at least 35% covered by solid aluminum metal. In some embodiments, second portion 624''''' of surface region 620'''' is at least 40% covered by solid aluminum metal. In some embodiments, second portion 624''''' of surface region 620'''' is at least 45% covered by solid aluminum metal. In some embodiments, second portion 624''''' of surface region 620'''' is at least 50% covered by solid aluminum metal. In some embodiments, second portion 624''''' of surface region 620'''' is at least 55% covered by solid aluminum metal. In some embodiments, second portion 624''''' of surface region 620'''' is at least 60% covered by solid aluminum metal.In some embodiments, second portion 624''''' of surface region 620'''' is at least 65% covered by solid aluminum metal. In some embodiments, second portion 624''''' of surface region 620'''' is at least 70% covered by solid aluminum metal. In some embodiments, second portion 624''''' of surface region 620'''' is at least 75% covered by solid aluminum metal. In some embodiments, second portion 624''''' of surface region 620'''' is at least 80% covered by solid aluminum metal. In some embodiments, second portion 624''''' of surface region 620'''' is at least 85% covered by solid aluminum metal. In some embodiments, second portion 624''''' of surface region 620'''' is at least 90% covered by solid aluminum metal. In some embodiments, second portion 624''''' of surface region 620'''' is at least 95% covered by solid aluminum metal. In some embodiments, the second portion 624'''''' of the surface area 620'''' is at least 100% covered by solid aluminum metal.

[0116] In some embodiments, the solid aluminum metal covering first portion 622'''''' and / or second portion 624'''''' of surface region 620'''''' is in the form of a film. In some embodiments, the film has a thickness between 1 μm and 500 μm. In some embodiments, first portion 622'''''' and / or second portion 624'''''' of surface region 620'''''' is free of solid aluminum metal.

[0117] FIG. 7A is a front view of one embodiment of a product 700, in which a TiB2 substrate 702 has a slot 706 as a guide mechanism, and solid aluminum metal 712 covers the TiB2 substrate 702. In FIG. 7A, a portion of the solid aluminum metal 712 is shown peripherally or transparently to reveal the surface structure of the substrate 702. A first protrusion 704A and a second protrusion 704B define a slot 706 that extends upward from a base 708. FIG. 7B is a cross section taken along dashed line 7B shown in FIG. 7A. FIG. 7C is a first side view of the cross section taken along dashed line 7C shown in FIG. 7A.

[0118] FIG. 7D is a front view of one embodiment of a product 700' in which a TiB2 substrate 702' has a slot 706' as a guide feature, with solid aluminum metal 712' covering a portion of the slot 706'. A first protrusion 704A' and a second protrusion 704B' extend upwardly from a base 708', thereby defining a slot 706'. FIG. 7E is a cross section taken along dashed line 7E shown in FIG. 7D. As shown in FIG. 7E, a middle portion 714' of the slot 706' is free of solid aluminum metal 712'. The front and back of the slot 706' are shown as having solid aluminum metal 712'. FIG. 7F is a first side view of the embodiment shown in FIG. 7D.

[0119] The embodiments shown in Figures 7D, 7E, and 7F and the embodiments shown in Figures 7A, 7B, and 7C are the same or similar except for the differences described herein. For example, the amount of solid aluminum metal 712 / 712' covering the TiB2 substrate 702 / 702' varies from embodiment to embodiment. In the embodiment of Figures 7A, 7B, and 7C, the solid aluminum metal 712 covers almost the entire TiB2 substrate 702. Only a portion of the base 708 is covered with the solid aluminum metal 712. The slot 706 is completely filled with the solid aluminum metal 712. In contrast, Figures 7D, 7E, and 7F do not have the solid aluminum metal 712' outside the TiB2 substrate 702'. Only a portion of the slot 706' is filled with the solid aluminum metal 712'.

[0120] Figures 7A, 7B, 7C, 7D, 7E, and 7F are the same as or similar to the embodiments of Figures 3A, 3B, and 3C. One difference is that Figures 3A, 3B, and 3C do not show solid aluminum metal on the TiB2 substrate surface or at least partially covering them. The description of the solid aluminum metal in the embodiments of Figures 6A-6N also applies to the solid aluminum metal in Figures 7A-7F.

[0121] FIG. 8A is a front view of one embodiment of a product 800, in which a TiB2 substrate 802 has a number of grooves 806 as a guiding feature, and a solid aluminum metal 812 covers the TiB2 substrate 802. In FIG. 8A, a portion of the solid aluminum metal 812 is shown peripherally or transparently to reveal the surface structure of the substrate 802. FIG. 8B is a first side view of a cross section taken along line 8B shown in FIG. 8A. FIG. 8C is an enlarged partial cross-sectional view of the embodiment shown in FIG. 8A, as indicated by the dashed line in FIG. 8A. FIG. 8C includes a view of a first groove 806A, a second groove 806B, and a third groove 806C.

[0122] FIG 8D is a back view of one embodiment of product 800' where TiB2 substrate 802' has multiple grooves 806' as guiding features and solid aluminum metal 812' covers the front half of TiB2 substrate 802'. FIG 8E is a first side view of a cross section taken along line 8E shown in FIG 8D. FIG 8F is an enlarged partial cross-sectional view of the embodiment shown in FIG 8D, indicated by the dashed circle in FIG 8F.

[0123] The embodiments shown in Figures 8D, 8E, and 8F and the embodiments shown in Figures 8A, 8B, and 8C are the same or similar, except for the differences described herein. For example, the amount of solid aluminum metal 812 / 812' covering the TiB2 substrate 802 / 802' varies from embodiment to embodiment. In the embodiments of Figures 8A, 8B, and 8C, the solid aluminum metal 812 completely covers the TiB2 substrate 802. In contrast, the solid aluminum metal 812' in Figures 8D, 8E, and 8F covers only the front half of the TiB2 substrate 802'.

[0124] The embodiment of Figures 8A, 8B, 8C, 8D, 8E, and 8F is the same as or similar to the embodiment of Figures 4A, 4B, 4C, and 4D. One difference is that Figures 4A, 4B, 4C, and 4D do not show solid aluminum metal on the TiB2 substrate surface. Figures 8A, 8B, 8C, 8D, 8E, and 8F show solid aluminum metal 812 / 812' on the TiB2 substrate. The description of solid aluminum metal 612 / 712 of the embodiment of Figures 6A-6N and Figures 7A-7F also applies to solid aluminum metal 812 / 812' of Figures 8A-8F.

[0125] In FIGS. 8A-8F, the at least one guiding feature is a groove 806 / 806', and the solid aluminum metal 812 / 812' is at least partially contained within the groove 806 / 806'. The at least one groove 806 / 806' comprises a groove volume. In some embodiments, the solid aluminum metal 812 / 812' occupies at least 1% of the groove volume. In some embodiments, the solid aluminum metal 812 / 812' occupies at least 5% of the groove volume. In some embodiments, the solid aluminum metal 812 / 812' occupies at least 10% of the groove volume. In some embodiments, the solid aluminum metal 812 / 812' occupies at least 15% of the groove volume. In some embodiments, the solid aluminum metal 812 / 812' occupies at least 20% of the groove volume. In some embodiments, the solid aluminum metal 812 / 812' occupies at least 25% of the groove volume. In some embodiments, the solid aluminum metal 812 / 812' occupies at least 30% of the groove volume. In some embodiments, the solid aluminum metal 812 / 812' occupies at least 35% of the groove volume. In some embodiments, the solid aluminum metal 812 / 812' occupies at least 40% of the groove volume. In some embodiments, the solid aluminum metal 812 / 812' occupies at least 45% of the groove volume. In some embodiments, the solid aluminum metal 812 / 812' occupies at least 50% of the groove volume. In some embodiments, the solid aluminum metal 812 / 812' occupies at least 55% of the groove volume. In some embodiments, the solid aluminum metal 812 / 812' occupies at least 60% of the groove volume. In some embodiments, the solid aluminum metal 812 / 812' occupies at least 65% of the groove volume. In some embodiments, the solid aluminum metal 812 / 812' occupies at least 70% of the groove volume. In some embodiments, the solid aluminum metal 812 / 812' occupies at least 75% of the groove volume. In some embodiments, the solid aluminum metal 812 / 812' occupies at least 80% of the groove volume. In some embodiments, the solid aluminum metal 812 / 812' occupies at least 85% of the groove volume.In some embodiments, the solid aluminum metal 812 / 812' occupies at least 90% of the groove volume. In some embodiments, the solid aluminum metal 812 / 812' occupies at least 95% of the groove volume. In some embodiments, the solid aluminum metal 812 / 812' occupies at least 100% of the groove volume.

[0126] 9 is a close-up view of a portion of an embodiment of an article 900 of a TiB2 substrate 902 having pores 904 and solid aluminum metal 906, according to some embodiments. In some embodiments, the TiB2 substrate 902 is a web of TiB2, e.g., a sponge-like structure.

[0127] In some embodiments, the article 900 comprises a TiB2 substrate 902 that is a web of TiB2 and a solid aluminum metal 906 at least partially covering a surface of the web of TiB2 substrate 902. The web of TiB2 substrate 902 defines pores 904 within the web of TiB2.

[0128] In some embodiments, the solid aluminum metal 906 has voids. The solid aluminum metal 906 may be hot when the solid aluminum metal 906 fills the pores 904. When the solid aluminum metal 906 cools, there may be spaces (e.g., pores or voids) between the solid aluminum metal 906 and the pores of the TiB2 substrate 902. The pores 904 have voids in the TiB2 substrate 902 web that define the pore volume of the TiB2 substrate 902. In some embodiments, the solid aluminum metal 906 occupies at least 1% of the pore volume. In some embodiments, the solid aluminum metal 906 occupies at least 5% of the pore volume. In some embodiments, the solid aluminum metal 906 occupies at least 10% of the pore volume. In some embodiments, the solid aluminum metal 906 occupies at least 15% of the pore volume. In some embodiments, the solid aluminum metal 906 occupies at least 20% of the pore volume. In some embodiments, the solid aluminum metal 906 occupies at least 25% of the pore volume. In some embodiments, the solid aluminum metal 906 occupies at least 30% of the pore volume. In some embodiments, the solid aluminum metal 906 occupies at least 35% of the pore volume. In some embodiments, the solid aluminum metal 906 occupies at least 40% of the pore volume. In some embodiments, the solid aluminum metal 906 occupies at least 45% of the pore volume. In some embodiments, the solid aluminum metal 906 occupies at least 50% of the pore volume. In some embodiments, the solid aluminum metal 906 occupies at least 55% of the pore volume. In some embodiments, the solid aluminum metal 906 occupies at least 60% of the pore volume. In some embodiments, the solid aluminum metal 906 occupies at least 65% of the pore volume. In some embodiments, the solid aluminum metal 906 occupies at least 70% of the pore volume. In some embodiments, the solid aluminum metal 906 occupies at least 75% of the pore volume. In some embodiments, the solid aluminum metal 906 occupies at least 80% of the pore volume.In some embodiments, the solid aluminum metal 906 occupies at least 85% of the pore volume. In some embodiments, the solid aluminum metal 906 occupies at least 90% of the pore volume.

[0129] The porosity of the TiB2 substrate 902 can have any suitable porous structure. The porosity of the TiB2 substrate 902 can be an interconnected porous structure, with at least a portion of the pores in fluid communication with each other to facilitate the movement of the wettable material from a first location to a second location (e.g., from a first predetermined location to a second predetermined location). Thus, the interconnected porous structure can be considered an open pore structure. In some embodiments, the porosity of the TiB2 substrate 902 can result in a random porous structure. In some embodiments, the porosity of the TiB2 substrate 902 can be an oriented porous structure. In some embodiments, the porosity of the oriented porous structure of the TiB2 substrate 902 can be a porosity gradient. In some embodiments, the porosity gradient of the oriented porous structure of the TiB2 substrate 902 can vary along a three-dimensional gradient (i.e., the porosity gradient can vary along the X-axis, the Y-axis, and the Z-axis of the TiB2 substrate 902). In some embodiments, the porosity gradient of the oriented porous structure of the TiB2 substrate 902 increases or decreases toward the center of the TiB2 substrate 902. In some embodiments, the porosity gradient of the oriented porous structure of the TiB2 substrate 902 can increase and / or decrease throughout the TiB2 substrate 902. For example, the porosity gradient of the oriented porous structure of the TiB2 substrate 902 can increase, decrease, and then increase from one end of the TiB2 substrate 902 to the other end of the TiB2 substrate 902.

[0130] The aluminum refining cell or aluminum electrolytic cell can include any of the TiB2 substrates described herein. In some embodiments, at least one of the TiB2 substrates is an electrode of the aluminum refining cell or aluminum electrolytic cell. In some embodiments, at least one of the TiB2 substrates is an induction device, the induction device configured to induce liquid aluminum metal in a predetermined direction when no electric current is applied.

[0131] The article may comprise a TiB2 substrate as described herein having at least one directing feature and solid aluminum metal at least partially covering a surface of the TiB2 substrate. The solid aluminum metal may be at least partially within the at least one directing feature. In some embodiments, the at least one directing feature comprises a void volume. In some embodiments, at least 1% of the void volume comprises solid aluminum metal. In some embodiments, at least 5% of the void volume comprises solid aluminum metal. In some embodiments, at least 10% of the void volume comprises solid aluminum metal. In some embodiments, at least 15% of the void volume comprises solid aluminum metal. In some embodiments, at least 20% of the void volume comprises solid aluminum metal. In some embodiments, at least 25% of the void volume comprises solid aluminum metal. In some embodiments, at least 30% of the void volume comprises solid aluminum metal. In some embodiments, at least 35% of the void volume comprises solid aluminum metal. In some embodiments, at least 40% of the void volume comprises solid aluminum metal. In some embodiments, at least 45% of the void volume comprises solid aluminum metal. In some embodiments, at least 50% of the void volume comprises solid aluminum metal. In some embodiments, at least 55% of the void volume comprises solid aluminum metal. In some embodiments, at least 60% of the void volume comprises solid aluminum metal. In some embodiments, at least 65% of the void volume comprises solid aluminum metal. In some embodiments, at least 70% of the void volume comprises solid aluminum metal. In some embodiments, at least 75% of the void volume comprises solid aluminum metal. In some embodiments, at least 80% of the void volume comprises solid aluminum metal. In some embodiments, at least 85% of the void volume comprises solid aluminum metal. In some embodiments, at least 90% of the void volume comprises solid aluminum metal. In some embodiments, at least 95% of the void volume comprises solid aluminum metal.In some embodiments, at least 100% of the void volume comprises solid aluminum metal. EXAMPLES

[0132] Example 1 - Laboratory scale testing <Manufacturing of porous TiB2 substrate (TiB2 foam)>

[0133] Four different TiB2 foam samples, each measuring about 3 inches (H) x 2 inches (W) x 0.5 inches (D), were fabricated with porosities of about 10, 20, 30, and 45 PPI, respectively. The TiB2 foam samples were fabricated by immersing polyurethane foams of various pore sizes into an aqueous slurry having TiB2 particles therein. The TiB2 coated foams were then rolled between a set of parallel rollers with a defined gap thickness, which compresses the infiltrated foam and expels the waste slurry. The rolled TiB2 foams were then hung in a drying oven. In some cases, the process was repeated, re-immersing the coated foams in the aqueous slurry and then air-dried. The final dried TiB2 foams were then sintered by heating at a temperature of about 1850°C. Figure 10 shows an example of the sintered final product. The sintered final products had continuous interconnected pores with pore sizes of approximately 10, 20, 30, and 45 PPI corresponding to the pore sizes of the respective polyurethane foams. As shown in Figure 10, the pore structure is an open pore structure that allows fluid to move from one predetermined location to another.

[0134] <Water Wetting Test> As shown in FIG. 11, each of the four TiB2 foam samples (at approximately 10, 20, 30, and 45 PPI) was wrapped with two pieces of tissue paper, one piece of tissue paper on the top of the sample, and one piece of tissue paper around the center of the sample. Then, the bottom of the TiB2 sample was placed in water 0.25 inches well below the center of the sample to test the sample's ability to promote the mass transfer of water by capillary action. After approximately 12 hours, the samples were evaluated. None of the tissues in the approximately 10 PPI sample were wet or soaked, indicating that no capillary action had occurred. In the approximately 20 PPI sample, the tissue in the center was wet and the tissue on the top was dry. This indicated that some capillary action had occurred. In both the approximately 30 and 45 PPI samples, the tissues in the center and on the top were wet, indicating that a fairly large capillary action had occurred.

[0135] <Penetration of Aluminum Metal into TiB2 Foam> The sintered TiB2 foam was immersed in molten aluminum for 1 minute and then air-cooled. After being completely cooled, each of the four TiB2 foam samples was placed in a slot approximately 0.5 inches deep in the graphite stage of three separate crucibles (crucible #1, crucible #2, crucible #3, further described below). Each of the three crucibles was placed in the furnace and heated to 900 °C in argon. A purified molten aluminum composition (pure aluminum pellets) and a molten bath composition were placed in each crucible. The composition of the molten bath was cryolite-based and contained NaF, AlF3, and CaF2 components.

[0136] The crucibles with the four TiB2 foam samples, molten aluminum, and cryolite were held at 900 °C for approximately 48 hours. As shown in FIG. 12, in crucible #1, the four TiB2 foam samples were completely immersed in molten aluminum for 48 hours. In crucibles #2 and #3, the four TiB2 foam samples were partially immersed in molten aluminum approximately 1 and 2 inches respectively, and the remaining foam was exposed to the molten bath for 48 hours.

[0137] As shown in FIGS. 13A and 13B, after the test at 900° C. for 48 hours, no corrosion was observed in any of the crucibles for the four TiB2 foam samples, indicating that the samples were wetted by the molten aluminum by capillary action promoted by the pores of the foam. The molten aluminum protects the TiB2 from corrosion by cryolite.

[0138] Example 2 - Larger Laboratory Scale Tests <Manufacture of TiB2 Foam Samples>

[0139] Two separate TiB2 foam samples, each having dimensions of approximately 16 inches (H) × 2 inches (W) × 0.5 inches (D), were manufactured by the process of the foam samples of Example 1. The sintered final products of the two TiB2 foam samples had continuously interconnected pores with pore sizes of approximately 20 and 30 PPI, corresponding to the pore sizes of the respective polyurethane foams.

[0140] <Penetration of Aluminum Metal into TiB2 Foam> Two untreated TiB2 foam samples were placed in slots approximately 2 inches deep in the graphite base of the crucible. Before placing them on the graphite base, a purified molten aluminum composition (pure aluminum pellets) and a molten bath composition (which is cryolite-based and contains NaF, AlF3, and CaF2 components) were placed in each crucible, and each crucible was placed in the furnace and heated to 900° C. in argon. After heating, each of the two TiB2 foam samples was placed in the crucible. Then, each crucible having the TiB2 foam sample, molten aluminum, and cryolite was maintained at 900° C. After a test of about 10 minutes, the two TiB2 foam samples were removed from the crucible, and molten aluminum was detected at the top of the samples. Similar to Example 1, no corrosion was observed in either of the two TiB2 foam samples, indicating that the samples were wetted by the molten aluminum up to about 14 inches by capillary action promoted by the pores of the foam. The molten aluminum protects the TiB2 from corrosion by cryolite.

[0141] Although many embodiments of the present disclosure have been described, it is understood that these embodiments are illustrative and not limiting, and that many variations will be apparent to those skilled in the art. The various steps may be performed in any desired order (and any desired steps may be added and / or any desired steps may be removed). For example, the features and characteristics of the guiding features (e.g., slots, holes, or grooves) may be used with either the product and / or the TiB2 substrate, or alone. The features and characteristics of the solid aluminum metal described in any of the embodiments may be used in any other embodiment described herein. The exemplary embodiments of guiding features and solid aluminum metallization are not intended to be exhaustive. The features and characteristics of the present disclosure may be combined in any manner.

Claims

1. A product, a ceramic substrate having a guide mechanism; the guiding mechanism is configured to guide the ceramic wettable material in a predetermined direction; product.

2. The article of manufacture of claim 1 , wherein the ceramic wettable material comprises aluminum.

3. 3. The article of manufacture of claim 2, wherein the aluminum is selected from the group consisting of aluminum alloys, metallic aluminum, and combinations thereof.

4. The article of manufacture of claim 1 , wherein the guide features are selected from the group consisting of slots, grooves, pores, channels, and combinations thereof.

5. The article of manufacture of claim 4 , wherein the guide features comprise pores.

6. The article of manufacture of claim 5 , wherein the guidance feature comprises porosity of the ceramic substrate.

7. The article of claim 6 , wherein the pores comprise an oriented porous structure, the oriented porous structure having a porosity gradient.

8. The article of manufacture of claim 4 , wherein the guide mechanism comprises at least one slot, the at least one slot extending through a thickness of the ceramic substrate.

9. 5. The article of manufacture of claim 4, wherein the ceramic substrate comprises a first protrusion and a second protrusion, and the guide mechanism comprises a slot defined by an inner surface of the first protrusion and an inner surface of the second protrusion.

10. The article of manufacture of claim 4 , wherein the guide mechanism comprises at least one groove, the at least one groove extending partially into the ceramic substrate.

11. 10. The article of manufacture of claim 1, wherein the ceramic substrate is a three-dimensional geometric shape, the three-dimensional geometric shape being at least one of a rectangular shape, a square shape, a triangular shape, an oval shape, or an oblong shape.

12. The article of manufacture of any one of claims 1 to 11, wherein the directing mechanism is configured to direct the ceramic wettable material by capillary action.

13. A product, (a) a ceramic substrate having at least one induction feature; (b) solid aluminum metal at least partially covering a surface of the ceramic substrate.

14. 14. The article of manufacture of claim 13, wherein said solid aluminum metal is at least partially contained within said at least one guide mechanism.

15. 1. A method comprising:

1. Manufacturing a ceramic product with a guidance mechanism, comprising: the induction mechanism comprises: (a) a plurality of pores in or on the ceramic article; or (b) a predetermined geometric feature in or on the ceramic article; or (c) a combination of (a) and (b); The method, wherein the directing mechanism is configured to direct the ceramic wetting material in a predetermined direction.

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