Abstract
This study investigates the phase formation and smelting process of a complex Al-Si-Mn alloy based on thermodynamic diagram analysis (TDA). The Fe-Si-Mn-Al system was analyzed considering binary and ternary subsystems, and the standard Gibbs free energy of formation of selected ternary compounds was calculated using the additive method. Based on these results, phase equilibrium diagrams were constructed, and the system was tetrahedralized, leading to the identification of 15 thermodynamically stable tetrahedra. It was established that compositions of industrial interest are predominantly localized within tetrahedra enriched in silicide and aluminosilicide phases, particularly FeSi-Fe2Al2Si-Fe3Al11Si6-Mn5Si3. Experimental verification was carried out in a 250 kVA ore-thermal furnace using manganese ore, high-ash coal, and quartzite. The smelting process was conducted under slag-free conditions with stable electrical operation. The obtained alloy had the following composition (wt.%): Fe ~ 12.1, Si ~ 44.7, Mn ~ 34.5, and Al ~ 5.1, with low impurity levels (C < 0.5%, S < 0.02%, p < 0.09%). Microstructural analysis using SEM-EDS confirmed the formation of silicide (FeSi, Mn5Si3) and aluminosilicide phases, which ensure the structural stability of the alloy. It is shown that the localization of alloy compositions within specific tetrahedra of the Fe-Si-Mn-Al system prevents self-disintegration. The results demonstrate that TDA is an effective tool for predicting phase composition and optimizing the production technology of complex ferroalloys.