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The technologies of titanium powder

metallurgy
Vladimir Moxson

JOM

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 Overview
The Technologies of Titanium Powder
Metallurgy
F.H. Froes, S.J. Mashl, V.S. Moxson, J.C. Hebeisen, and V.A. Duz
Titanium alloys exhibit attractive
mechanical properties but they are
expensive. This paper reviews the cur-
rent status of titanium powder metal-
lurgy which offers near-net shape cost-
effective approaches to the fabrication
of components.
INTRODUCTION
A major problem with the use of
titanium is its high cost.1–5 One of the
ways to get around this problem is by
use of a near-net shape (NNS) process
such as powder metallurgy (PM).6–9
This paper addresses NNS titanium
PM fabrication methods including
prealloyed (PA) and blended elemental
(BE) techniques, and metal injection
molding (MIM).
The PA technique involves prealloyed
powder and generally, hot isostatic
pressing (HIPing). It is normally higher
cost, but with enhanced mechanical
properties compared to the BE method.
In the BE method, sponge fines and
appropriate alloying additions (gener-
ally in the form of a cost-effective
master alloy such as Al-V) are blended
together, then cold pressed and sintered
to produce nearly full density and
a homogenous chemistry. The MIM
approach is based upon technology
developed for injection molding of
plastics and can use either a BE or
PA starting stock. The HIPing of BE
compacts can be used to increase density
and enhance mechanical properties,
albeit with an increase in cost.
NEAR-NET SHAPE
FABRICATION METHODS
As noted, the PA approach normally
involves compaction by HIPing below
the beta transus temperature (which is
about 996°C for the Ti-6Al-4V alloy)
to full density (see reference 10 for
46
Titanium
the schematics).11 The BE technique is hydrogenated titanium powder rather
carried out by cold pressing in a die or than normal fines, which results in
sometimes by cold-isostatic pressing a marked increase in the as-sintered
(CIPing) followed by sintering well density (Figure 2) and a relatively small
above the beta transus temperature beta grain size.12 Importantly, the high
(e.g., 1,260°C for 4 h for the Ti-6Al-4V density is virtually independent of the
alloy).6–9 Over the years, a number compaction pressure used, which is of
of improvements to the BE approach great significance for complex parts.
have been made including secondary The MIM process is based upon the
operations such as hot forging or injection molding of plastics, a process
HIPing. These improvements are aimed developed for long production runs
at increasing the density of the product of small (normally less than 400 g)
(Figure 1) to improve the mechanical complex-shaped parts in a cost-effective
properties. manner. By increasing the metal (or
Recently, a significant improvement ceramic) particle content, MIM evolved
in BE material was achieved by using into a process for production of high-
a 100 µm b 100 µm
Figure 1. (a) A photomicrograph of a Ti-6Al-4V alloy produced from commercial-purity
titanium sponge fines blended with Al-V master alloy, followed by CIPing and sintering
to a nominal 95% of theoretical density. (b) The same material after HIPing. The porosity
is no longer apparent.10
100 7
98 5 Figure 2. The den-
6
Relative 'Density (%)
96 sity of Ti-6Al-4V
4 compacts after sin-
94
92 3 tering. Conditions 5
1 and 7 used hydrided
90 powder and exhib-
88 2 ited by far the high-
86 est and most uni-
84 form densities after
82 sintering.12
300 400 500 600 700 800 900 1000
Molding Pressure (MPa)
JOM • November 2004
density metal, intermetallic, or ceramic
components (for a schematic, see figure
in Reference 13).14
Much of the early work on developing
a viable titanium MIM process was
plagued by the unavailability of suitable
powder, inadequate protection of the
titanium during elevated-temperature
processing, and less-than-optimum
binders for a material as reactive as
titanium, particularly oxygen pick-up.14
However, some MIM practitioners have
now learned what the titanium com-
munity has long known—that titanium
is the universal solvent and must be
treated accordingly.
Recent work by Praxis Technology15
and other companies has led to much
better control of the oxygen level,
particularly in the Ti-6Al-4V alloy
compacts can be also modified signifi- approaches discussed in this paper are
cantly using thermohydrogen process- shown in Figures 4–6.
ing, 19,20 which results in a marked
CONCLUSIONS
increase in fatigue behavior.
With the advent of high-quality,
COMPONENTS
lower-cost titanium powders, the empha-
Besides controlling the basic micro- sis in titanium PM technology has cen-
structure of titanium PM compacts tered on production of near-net shapes
and minimizing porosity (both factors with acceptable levels of mechanical
to optimize mechanical properties), properties. The prealloyed, blended
a high-integrity cost-effective part elemental, and metal injection molding
necessitates fabrication of an NNS approaches are all looking attractive
requiring little or no machining.5–10 and should post significant growth in
Examples of parts produced by the three the next few years.
180
1,200 Ti-6Al-4V
Axial Fatigue 160
1,000 Smooth, RoomTemp.
R = +0.1, Typical Annealed Data 140

Maximum Stress (MN/m2)

where the ASTM specification requires
800 Wrought 120
a maximum of 0.2 wt.%.
Figure 3. The fatigue 100

KSI
THE EFFECT OF POROSITY behavior of >99% dense 600 Prealloyed
ON MECHANICAL material compared to cast
Powder (HIP) 80
PROPERTIES and wrought (ingot), cast 400 Elemental Powder 60
and prealloyed PM mate-
rial. The >99% dense mate- Cast 40
The strength and ductility of PM 200
rial (actual data points
products improves significantly as the shown) exhibits an endur- 20
porosity decreases (Table I).10 Porosity ance limit of 415 MPa. 0
has an even greater effect on initiation- 103 104 105 106 107
related properties such as S-N fatigue.16 Cycles To Failure (Nf)
Careful control of the size of the
titanium powder and master alloy
(60Al40V) leads to a significant density
enhancement and concurrent ductility
improvement. Table I. Typical Mechanical Properties of Blended Elemental PM Ti-6Al-4V Products10
The ductility can be increased even UTS 0.2% Yield Elongation % Reduction
further by limiting beta grain growth with Condition* (MPa) (MPa) (%) of Area
dispersion of second-phase particles, H.C. as-sintered* 745 670 5.0 3.1
such as Y2O3 or B4C (Table II).17 A H.C. after HIP 855 750 9.0 20.3
further factor is the shape of the porosity. E.L.C. as-sintered** 910 800 8.3 12.1
E.L.C. after HIP 945 840 11.9 26.5
It is clear from work on steels that as Mil-T-9046 annealed (wrought specification) 895 825 10 25
the notch factor increases the endurance ASTM B-348 grade 5 (casting specification) 765 695 5 7
limit is degraded.18 *H.C.—high chloride, 1,500 ppm; **E.L.C.—extra low chloride, <10 ppm
The fatigue behavior of >99% dense
BE Ti-6Al-4V material approaches that
of cast and wrought (ingot metallurgy)
material (shown in Figure 3).16 Table II. Mechanical Properties of Ti-6Al-4V: Effect of Particle Size
Advances in PA HIPed titanium PM and Microstructural Controla 18
components have made it possible to Density UTS 0.2% YS El. RA Fatigue Strengthb
produce fully dense components with Condition (%) (MPa) (MPa) (%) (%) (MPa)
mechanical properties at least equivalent Nc – Sintered 96.5 915 815 7.1 10.8 160
to those found in wrought titanium. Nc – HIPed 100.0 970 860 15.1 36.9 400
Cd – NMCe 99.6 980 860 14.7 35.8 225
The major thrust in PA titanium alloy C d – Y 2O 3f 99.6 1,020 910 11.7 22.7 280
technology is to produce a refined, Cd – B4Cf 99.7 1,110 980 12.1 17.7 345
homogeneous, and isotropic micro- a. CIP 480 MPa, sintered 1,250°C – 2 h.
b. Rotating bending at 107 cycles.
structure regardless of the titanium alloy c. Ti 45–150 µm, 60Al40V master alloy average 20 µm (< 45 µm).
composition used. d. Ti 30 (< 45 µm): 60 (45–100 µm), 60Al40V master alloy average 6 µm (< 45 µm).
e. No addition to control microstructure.
The microstructure of Ti-6Al-4V f. 0.1–0.2 mass percentage of addition (B4C 5 µm).

2004 November • JOM 47


Figure 4. Ti-6Al-4V parts
produced via a BE press-
and-sinter and titanium
hydride: (1) connecting rod
with big end cap, (2) saddles
of inlet and exhaust valves,
(3) plate of valve spring, (4)
driving pulley of distributing
shaft, (5) roller of strap
tension gear, (6) screw nut,
(7) embedding filter, fuel
pump, and (8) embedding
filter.12 (Courtesy Ukraine
Titanium Institute.)
Figure 5. (a) A Ti-6Al-4V
trunnion produced by the
direct HIPing of plasma
rotating electrode powder
within a (b) near-net-shape
a b
sheet metal capsule.10
Figure 6. Cosmetic titanium applications made using Praxis Technology binder systems.15
(Parts courtesy of Titanium Products.)
48
ACKNOWLEDGEMENTS
The authors acknowledge the contri-
butions of C. Draney, J. Grohowski,
F. Sun, and C.F. Yolton in developing the
data reported in this paper. In addition,
the assistance of Holly Palmer in
manuscript preparation is appreciated.
References
1. F.H. Froes, D. Eylon, and H.B. Bomberger, Titanium
Technology: Current Status and Future Trends (Dayton,
OH: TDA, 1985).
2. F.H. Froes, T-L Yau, and H.G. Weidinger, Structure
and Properties of Non-Ferrous Alloys, 6 (8) (1996),
p. 399.
3. F.H. (Sam) Froes, Handbook of Advanced Materials,
editor-in-chief James K. Wessel (New York: McGraw-Hill,
2001), p. 271.
4. F.H. (Sam) Froes, Handbook of Chemical Industry
Economics, Inorganic, editor-in-chief Jeff Ellis (New
York: John Wiley and Sons, 2001).
5. Brian E. Hurless and F.H. (Sam) Froes, Advanced
Materials and Processes, (December 2002), p. 37.
6. F.H. (Sam) Froes et al., Titanium P/M in Aerospace
and Automotive Components (Princeton, NJ: MPIF,
in press).
7. F.H. Froes and D. Eylon, International Materials
Reviews, 35 (1990), p. 162.
8. F.H. Froes and C. Suryanarayana, “Reviews in
Particulate Materials, 1 (1993), p. 223.
9. F.H. (Sam) Froes, Metal Powder Report, 57 (4)
(2002).
10. S.J. Mashl and J.C. Hebeisen, Automotive Fatigue
Design and Applications, compiled by R. Chernenkoff
and W. Jandeska, Jr. (Princeton, NJ: MPIF, 2003),
in press.
11. C. Draney, F.H. (Sam) Froes, and J.C. Hebeisen,
Materials Technology/Advanced Performance Materials,
to be published.
12. O. Ivasishin et al., High Performance Metallic
Materials for Cost-Sensitive Applications, ed. F.H. Froes
et al. (Warrendale, PA: TMS, 2002), pp. 117–128.
13. R.M German, Powder Metallurgy Science, 2nd
Edition (Princeton, NJ: MPIF, 1994), p. 192 et seq.
14. F.H. (Sam) Froes and R.M. German, Metal Powder
Report, 55 (6) (2000), p. 12.
15. J.A. Grohowski, B.C. Sherman, and J.T. Strauss,
(Princeton, NJ: MPIF, 2003).
16. V.S. Moxson et al., Automotive Fatigue Design and
Applications, ed. R. Chernenkoff and W. Jandeska, Jr.
(Princeton, NJ: MPIF, 2003) In press.
17. H. Fujii et al., Nippon Steel Tech. Rpt., No. 85
(January 2002), p. 77.
18. G. Hoffman and C.M. Sonsino, Automotive Fatigue
Design and Applications, ed. R. Chernenkoff and W.
Jandeska, Jr. (Princeton, NJ: MPIF, 2003), in press.
19. O.N. Senkov, J.J. Jonas, and F.H. Froes, JOM,
48 (7) (1996), p. 42.
20. F.H. (Sam) Froes, O.N. Senkov and J. Qazi, IMR,
49 (3–4) (2004), p. 227.
F.H. Froes is with IMAP at the University of Idaho
in Moscow, ID. S.J. Mashl and J.C. Hebeisen are
with Bodycote HIP–North America in Andover,
MA. V.S. Moxson and V.A. Duz are with ADMA
Products, Inc.in Twinsburg, OH.
For more information, contact F.H. Froes, University
of Idaho, McClure Bldg., Room 437, Moscow, ID
83844-3026, e-mail imap@uidaho.edu.
JOM • November 2004