In order to reliably design and operate different powder processes, an understanding of the dynamic flow, shear and bulk properties of powders is required. Generally, powders are evaluated by several techniques that determine their flow, shear and bulk properties. The techniques can include compression tests, shear tests, angle of repose, flow of powder in a funnel, tapped density and many others. In order to minimize the number of instruments required to characterise the powder and eliminate operator error, automated powder rheometers that can do most of the required tests have been developed. The FT4 powder rheometer is one of these and has found widespread use in the pharmaceutical industry. In this study, the FT4 powder rheometer was used to characterise two metallic titanium powders with different particle sizes, namely CSIR Ti-45μm (Fine Powder) and CSIR Ti +45-180μm (Coarse Powder). Their particle size, particle size distribution, bulk densities, compressibility, cohesion, flowability index, effective angle of internal friction and wall friction angle were determined. Preliminary results of the study indicated that fine powder had a lower bulk density, was more compressible and more cohesive than the coarse powder. The fine powder had a lower flowability index compared to the coarse powder for both the Jenike and Peschl classification. The varying degrees of cohesion of these powders were confirmed by the cohesion values that were higher for the fine powder. The fine powder had a lower angle of internal friction but higher wall friction angle compared to the coarse powder.
Mechanical alloying (MA) is a simple and versatile dry powder processing technique that has been used for the manufacture of both equilibrium and metastable phases of commercially useful and scientifically interesting materials. It owes its origin to an industry need to develop a nickel-based super alloy for gas turbine applications that had both oxide dispersion strengthening and precipitation hardening. This far-from equilibrium powder metallurgy processing technique involves fracturing, welding and re-welding of powder particles in a High Energy Ball Mill (HEBM). MA is an economically viable process with important technical advantages. Its utmost advantage is in the synthesis of novel alloys, e.g., alloying of ordinarily immiscible elements, that is not possible by any other technique. As MA is a completely solid-state processing technique, the limitations imposed by phase diagrams do not apply to it. The MA process is capable of producing different types of metastable effects in a variety of alloy systems. Some of the metastable effects achieved by MA are solid solution formation and amorphisation. MA has the possibility of producing superior and enhanced materials than those produces by conventional methods. In this work a review of MA and its present and potential applications for Ti-based materials are presented.
The Council for Scientific and Industrial Research (CSIR) is developing a process to produce titanium by direct metallothermic reduction of titanium tetrachloride in a medium of molten salt. The product consists of agglomerates of small primary crystallites with a highly irregular morphology. The objective of this study is to characterize the powder and determine its suitability for consolidation by microwave energy. Recent developments in the use of microwave energy to sinter titanium powder compacts show that this is a cost effective and energy efficient method to obtain dense titanium products. The in-depth heating permits rapid processing times and preserves the fine grain structure in the final product, resulting in excellent mechanical properties. The composition, particle size distribution and morphology of the powder will be discussed as will the final density, microstructure and mechanical properties after microwave sintering.
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