A novel flux charging method and a crucible quenching method were employed to study the mechanism of solid fluxes refining method regarding the removal of oxide inclusions (Al2O3) from molten aluminum. Electrochemical polishing method was adopted to prepare surfaces of the samples. Through experiments, the morphology of the residual solidified flux in the solidified samples as well as the wetting action of the molten flux during refining were observed for the first time. Three wetting regimes denoted by absorbing regime, engulfing regime and penetration regime correlating with the removal of oxide films (the most typical and common oxide inclusions in molten aluminum) were proposed in terms of different types and distributions of oxide films and different size ratios of the molten flux to oxide films. Particularly, from a thermodynamic point of view, for the first time, the penetration regime provided concrete evidence that the practical oxide inclusions can be wet by molten flux under ambient fluid of molten aluminum. A spreading model was proposed, according to which ingredients and size parameters of practical solid fluxes can be optimized.
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