Efficient preparation of AlV65 alloy through aluminothermic reduction of sodium metavanadate precipitated from shale V-rich solution

• Direct use of sodium metavanadate from shale V-rich solutions bypasses the need for high-purity V2O5, reducing environmental impact and processing time. • Impurity migration analysis reveals that Al forms a separate slag phase with CaO, while Na volatilizes during reduction, preventing contamination of the alloy. • Iron content must be controlled (≤0.05 wt%) to avoid phase transitions (Al–V → Al–Fe → Fe–V) and ensure alloy uniformity. • The process yields a high-quality AlV65 alloy (66.56 wt% V, 33.14 wt% Al) with low impurity levels, offering a streamlined route for industrial Al–V alloy production.