Integrated high-performance and accurate shaping technology of low-cost powder metallurgy titanium alloys: A comprehensive review

The practical engineering applications of powder metallurgy (PM) Ti alloys produced through cold compaction and pressureless sintering are impeded by poor sintering densification, embrittlement caused by excessive O impurities, and severe sintering deformation resulting from the use of heterogeneous powder mixtures. This review presents a summary of our previous work on addressing the above challenges. Initially, we proposed a novel strategy using reaction-induced liquid phases to enhance sintering densification. Near-complete density (relative density exceeding 99%) was achieved by applying the above strategy and newly developed sintering aids. By focusing on the O-induced embrittlement issue, we determined the onset dissolution temperature of oxide films in the Ti matrix. On the basis of this finding, we established a design criterion for effective O scavengers that require reaction with oxide films before their dissolution. Consequently, a ductile PM Ti alloy was successfully obtained by introducing 0.3wt% NdB₆ as the O scavenger. Lastly, a powder-coating strategy was adopted to address the sintering deformation issue. The ultrafine size and shell-like distribution characteristics of coating particles ensured rapid dissolution and homogeneity in the Ti matrix, thereby facilitating linear shrinkage during sintering. As a result, geometrically complex Ti alloy parts with high dimensional accuracy were fabricated by using the coated powder. Our fundamental findings and related technical achievements enabled the development of an integrated production technology for the high-performance and accurate shaping of low-cost PM Ti alloys. Additionally, the primary engineering applications and progress in the industrialization practice of our developed technology are introduced in this review.