Vanadium–aluminum alloy is an important intermediate alloy for preparing aviation grade titanium alloys, and its product quality directly affects the finished product quality of titanium alloys. In this study, focusing on the problems of high powder content (19.8%) and low product yield in AlV55 alloy products, we conduct research on alloy quality control technology and implement a vanadium–aluminum alloy cooling crystallization control process. The research results indicate that there are three phases in AlV55 alloy, namely Al₈V₅, AlV, and Al₂V₃ phases. As the temperature decreases, the AlV phase gradually decomposes into Al₈V₅ phase and Al₂V₃ phase, and the proportion of Al₈V₅ phase is positively correlated with the fineness. Rapid cooling can reduce the formation of Al₈V₅ phase. The experimental results show that high-temperature water quenching can increase the proportion of vanadium–aluminum solid solution phase in the alloy from 19.03% to 31.76%, and reduce the fine powder rate to 13.2%, providing important product quality control means and technical support for the production of vanadium–aluminum alloys.

A novel high-efficiency industrialized clean production technology based on multi-stage gradient batching and smelting was proposed for the production of high-quality ferrovanadium. The thermodynamic mechanism of aluminothermic reduction equilibrium, alloy settlement and raw material impurity distribution were confirmed, and a multi-stage double-gradient aluminum addition pattern (DG-ADP), the highly efficient separation of molten slag and alloy, and typical impurity control standards of raw materials were achieved on the basis of a self-propagating high-temperature synthesis with an electric auxiliary heating (SHS-EAH) process. The reduction efficiency, separation efficiency and the comprehensive utilization rate of the secondary resources were significantly improved, as the whole total vanadium (T.V) content in the industrially produced residue slag reduced from 2.34 wt.% to 0.60 wt.%, while the corresponding smelting yield increased from 93.7 wt.% to 98.7 wt.% and the aluminum consumption decreased from 510 kg·t⁻¹ to 400 kg·t⁻¹. The multi-stage DG-ADP process enabled the internal circulation of vanadium-bearing materials in the ferrovanadium smelting system, as well as the external circulation of iron and residue slag in the same system, and finally achieved the zero discharge of solid and liquid waste from the ferrovanadium production line, which provides a brand-new perspective for the cleaner production of ferrovanadium alloy.