| About this Abstract |
| Meeting |
2025 TMS Annual Meeting & Exhibition
|
| Symposium
|
Advances in Titanium Technology
|
| Presentation Title |
Low-Energy Production of High-Quality Titanium Alloy Powders via Innovative DRA Process |
| Author(s) |
MD Emran Hossain, Pei Sun, Zhigang Zak Fang |
| On-Site Speaker (Planned) |
MD Emran Hossain |
| Abstract Scope |
The high cost and embodied energy of titanium and its alloys limit their applications despite strong market demand. While additive manufacturing (AM) reduces material waste and energy use, the high embodied energy of titanium feed materials offsets these gains. Typically, spherical titanium and titanium alloy powders for AM are produced via atomization from primary metal products, with titanium derived from the energy-intensive Kroll process. Our research presents a novel, energy-efficient method to produce spherical Ti-6Al-4V alloy powder directly from oxide mixtures. This method combines hydrogen-assisted magnesiothermic reduction (HAMR) and Granulation-Sintering and Deoxygenation (GSD) processes in an integrated Direct Reduction and Alloying (DRA) process. The resulting Ti-6Al-4V powders have low interstitial impurities, controlled particle size distribution, homogeneous composition, and excellent flowability for AM applications. Additionally, the DRA process significantly reduces energy consumption compared to conventional methods, highlighting its potential as a sustainable approach for producing titanium alloy powders. |
| Proceedings Inclusion? |
Planned: |
| Keywords |
Additive Manufacturing, Titanium, Powder Materials |