Electrolytic Iron Powder from a Caustic Soda Solution

Conditions for electrolytic deposition of iron powder from a slurry of iron III oxide in caustic soda solutions were investigated. The variables that influence the deposition the most were temperature (90°C), caustic soda concentration (600–800 g/l), and low current densities. Results from pilot‐plant studies were in good agreement with laboratory findings. Several photomicrographs of the deposits are included. Physical and chemical properties of the powders are listed. Results show that a ductile, dendritic deposit was obtained that could be ground up easily. The size of the dendrites was influenced greatly by conditions of deposition. Particle size distribution, particle shape, ductility, flow rate, purity, and compactability of several powders were examined. Tensile strength and elongation of sintered compacts were also studied.