This work investigated the possibility of the direct preparation of aluminum alloys by aluminothermic reduction of deep-sea nodules with a high excess of aluminum. The process was found to be unable to obtain aluminum alloy, but an aluminum-rich manganese-based alloy was obtained instead, being composed of intermetallics. The alloy was characterized in the as-reduced state, as well as after crushing and sintering in the temperature range of 800–950 °C. The sample sintered at 900 °C was also heat-treated by annealing at 800 °C for 3 h and rapidly cooled. It was observed that with the increasing sintering temperature, the original matrix phase Al11Mn14 was transformed into a duplex matrix with a structure corresponding to Al11Mn14 and Al4Cu9, and this mixture was further transformed to the matrix with the structure corresponding to Al4Cu9. Furthermore, the mechanical properties and wear resistance of the samples were described. The highest microhardness was reached in the sample, which was annealed after sintering. Sintered samples reached a lower wear rate because of the fragmentation of brittle intermetallics during crushing.

Deep-sea nodules are ores formed on the sea floor at depths of 3000 to 6000 m as a result of sedimentation. They range in size from 1 cm to 15 cm and contain mainly manganese and iron and other elements that are collected from the nodules by complex pyrometallurgical and hydrometallurgical processes. These other elements of interest are bound in the nodules mainly in the form of manganese and iron oxides. In order to achieve a high yield of metals bound in nodules in the form of oxides, it is necessary to disintegrate this arrangement in the lattice. This can be achieved by exposing the deep-sea nodules to a reducing condition. This paper deals with the one-step recovery of metals of interest from nodules using silicothermic reduction with 10% excess silicon over stoichiometry. The phase composition, microstructure and mechanical properties of the obtained reduced material were determined.

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