Titanium powder production via the Metalysis process

Development of the Fray-Farthing-Chen Cambridge Process: Towards the Sustainable Production of Titanium and Its Alloys

“…67 The obtained titanium alloy powder was spheroidised, and fabricated into a billet via hot isostatic pressing (HIP) and subjected to monotonic tensile testing. 20 The test result revealed that the ultimate tensile strength of this material is close to that of Ti-6Al-4V. 20 In summary, the FFC-Cambridge process can use various cheap and recycled feedstocks to produce titanium and specific alloys, making it a more resource sustainable and environmentally friendly process.…”

“…20 The test result revealed that the ultimate tensile strength of this material is close to that of Ti-6Al-4V. 20 In summary, the FFC-Cambridge process can use various cheap and recycled feedstocks to produce titanium and specific alloys, making it a more resource sustainable and environmentally friendly process. These alternative and low-cost feedstocks currently find little or no applications, but feeding them into the FFC-Cambridge process surely increases their values.…”

“…34,35,81 Since its initial conception, the FFC-Cambridge process has been used to fabricate numerous titanium alloys, such as Ti-6Al-4V, 36 Ni-35Ti-15Hf, 37 Ti-10V-2Fe-3Al, 20,38 Ti-W 34,35,81 Ti-Ni, 6,[39][40][41] TiFe, [42][43][44][45][46] and Ti-Mo. 20,47 It was also noted that the a-and b-phases in the Ti-Zr alloys could be easily tuned by controlling the electrolysis duration, which adjusts the oxygen content in the Ti-Zr alloys. 48 Most recently, the high-entropy alloys (e.g., TiNbTaZr and TiNbTaZrHf) have been fabricated using the FFC-Cambridge process, which further demonstrates its capabilities for alloy making.…”

“…S3a and S3b show the microstructures of the ground natural ilmenite feedstock before and after electroreduction, respectively. 66 More recently, low-cost and novel titanium alloys were produced directly from either synthetic rutile (i.e., rutile produced from ilmenite, with a transition metal element concentration of 3.7% and aluminium content below 1%), 21,67 or naturally occurring rutile ore (beach sand) 20 via the FFC-Cambridge process (see supplementary Fig. S3c and S3d).…”

“…50 kWh/kg Ti 6 ), environmentally unfriendly (> 2 kg CO 2 per kg Ti) and a semi-batch process. Thus, there have been continuous research and industrial efforts to improve or replace the Kroll process [7][8][9][10][11][12][13][14][15][16][17][18][19][20][21][22] as summarised in the supplementary Table S1.…”