Superalloy scraps are deemed as potential unconventional sources of rare metals. In this study, an ultrasonic leaching method with a two-stage separation process was proposed. A series of Eh-pH diagrams for rare metals was constructed, and the results indicated that the leaching and separation process could be realized by adjusting the potential and pH values of leaching solutions. In the ultrasonic leaching process, results showed that the economic leaching percentages of Re, Ni, Co, Al, and Cr were 92.3%, 95.2%, 98.5%, 98.7%, and 97.5%, respectively. Compared with conventional leaching, ultrasonic leaching can improve the leaching percentages of rare metals by approximately 20%. In the two-stage separation process, the optimal recovery efficiencies of Al and Cr were 94.6% and 82.1% at a pH of 4.5, and Ni and Co were 99.5% and 98.3% at a pH of 7.5. With a two-stage precipitate process, rare metals can be efficiently recovered without generating any waste acid.
