Abstract: Disclosed herein is a process that includes: (a) forming a powder blend by mixing Commercially Pure (C.P.) titanium powder, one or more hydrogenated titanium powders containing around 3.4 to around 3.9 weight % of hydrogen (e.g., hydrogenated titanium powders available or referred to nominally as “titanium hydride” or TiH2), and one or more hydrogenated titanium powders containing around 0.2 to around 3.4 weight % of hydrogen, or a mixture of the hydrogenated titanium powders without the C.P. titanium powder, (b) consolidating the powder blend by either compacting the powder blend using die pressing, direct powder rolling, cold isostatic pressing, impulse pressing, metal injection molding, other room temperature consolidation method, or combination thereof, at a pressure in the range of around 400 to around 960 MPa, or loose sintering, to provide a green compact having a density lower than that of a green compact formed from only C.P.

Abstract: A process including: (a) forming a powder blend by mixing titanium powders, (b) consolidating the powder blend by compacting to provide a green compact, (c) heating the green compact thereby releasing absorbed water from the titanium powder, (d) forming ?-phase titanium and releasing atomic hydrogen from the hydrogenated titanium by heating the green compact in an atmosphere of hydrogen emitted by the hydrogenated titanium, (e) reducing surface oxides on particles of the titanium powder with atomic hydrogen released by heating of the green compact, (f) diffusion-controlled chemical homogenizing of the green compact and densification of the green compact by heating followed by holding resulting in complete or partial dehydrogenation to form a cleaned and refined compact, (g) heating the cleaned and refined green compact in vacuum thereby sintering titanium to form a sintered dense compact, and (h) cooling the sintered dense compact to form a sintered near-net shaped article.

Abstract: A process including: (a) forming a powder blend by mixing titanium powders, (b) consolidating the powder blend by compacting to provide a green compact, (c) heating the green compact thereby releasing absorbed water from the titanium powder, (d) forming ?-phase titanium and releasing atomic hydrogen from the hydrogenated titanium by heating the green compact in an atmosphere of hydrogen emitted by the hydrogenated titanium, (e) reducing surface oxides on particles of the titanium powder with atomic hydrogen released by heating of the green compact, (f) diffusion-controlled chemical homogenizing of the green compact and densification of the green compact by heating followed by holding resulting in complete or partial dehydrogenation to form a cleaned and refined compact, (g) heating the cleaned and refined green compact in vacuum thereby sintering titanium to form a sintered dense compact, and (h) cooling the sintered dense compact to form a sintered near-net shaped article.

Abstract: The invention relates to manufacture of titanium articles from sintered powders. The cost-effective initial powder: 10-50 wt % of titanium powder having ?500 microns in particle size manufactured from underseparated titanium sponge comprising ?2 wt % of chlorine and ?2 wt % of magnesium; 10-90 wt % of a mixture of two hydrogenated powders A and B containing different amount of hydrogen; 0-90 wt % of standard grade refined titanium powder, and/or 5-50 wt % of alloying metal powders. The method includes: mixing powders, compacting the blend to density at least 60% of the theoretical density, crushing titanium hydride powders into fine fragments at pressure of 400-960 MPa, chemical cleaning and refining titanium powders by heating to 300-900° C. and holding for ?30 minutes, heating in vacuum at 1000-1350° C., holding for ?30 minutes, and cooling.

Abstract: The invention relates to the cost-effective manufacture of near-net shape titanium articles from sintered powders containing titanium and all required alloying elements. The cost-effective initial powder composition for subsequent room temperature consolidation and sintering contains: (a) 10-50 wt. % of underseparated titanium powder with ?500 ?m in particle size manufactured from underseparated titanium sponge comprising up to 2 wt. % of chlorine and up to 2 wt. % of magnesium. The underseparated titanium powder costs significantly less than that for fully separated powder of completely reduced sponge; (b) 10-90 wt. % of hydrogenated titanium powder, whereby this powder is a mixture of two hydrogenated powders A and B containing different amount of hydrogen: powder A contains amount of hydrogen in the range of 0.2-1 wt. % and powder B contains amount of hydrogen in the range of 2-3.9 wt. %.

Abstract: The process includes (a) mixing a titanium hydride powder having a particle size of ≦150 &mgr;m with alloying metal powders (master alloys or elemental metal powders) having a particle size in the range of {fraction (1/15)}-⅖ of the maximal particle size of titanium hydride powder, (b) compacting the resulting powder mixture by molding at the pressures of 400-1000 MPa, (c) heating up to the sintering temperature of the predetermined alloy composition at variable pressures in a furnace chamber: initial heating to 400° C. in vacuum of less than 10−2 Pa, then, heating to a temperature range of 400-900° C. with the pressures up to 104 Pa, which is controlled by hydrogen being emitted by the decomposition of titanium hydride contained in the compacted powdered alloy, and finally, heating to over 900° C. to the sintering temperature at the pressure continually decreasing to the starting vacuum level, and (d) sintering.

Abstract: The cost-effective titanium powder is manufactured by (a) magnesium-thermic reduction of titanium chlorides characterized by the formation of a hollow block of the reaction mass having an open cavity in the center of the block, (b) thermal-vacuum separation of the hollow block from excessive Mg and MgCl2 at 850-950° C. and residual pressure of 10−2-10−3 mm Hg, (c) cooling of obtained titanium hollow block in a H2-contained atmosphere at an excessive hydrogen pressure, (d) crushing the hydrogenated titanium block, (e) grinding the crushed titanium pieces into the powder combined with a hydro-metallurgical treatment of obtained titanium powder in a diluted aqueous solution of at least one chloride selected from magnesium chloride, sodium chloride, potassium chloride, or titanium chloride, and (f) drying and, optionally dehydrating the titanium powder ground to a predetermined particle size.