Abstract
A systematic review of factors affecting the viability of direct powder rolling (DPR) as a process route for producing low-cost titanium metal strips was conducted by consolidating performance and process data from published research. Included is a market analysis that was performed by sourcing price points from powder and wrought product suppliers. As a result of the typical oxygen levels (>0.2 wt %) in low-cost powders, the performance of the DPR product is estimated at best to be comparable to ASTM grade 3 and 4 wrought products. Furthermore, evidence supporting chlorine levels >0.02 wt % in low-cost (non-melt) commercially available powders suggest poor weldability, which restricts the application of DPR titanium strips. A comparison of price points for powder and wrought products showed that the potential for commercial viability is likely to exist only for thin gauge strips of <1 mm thickness, as the cost advantage diminishes as the strip thickness increases. Based on the DPR product profile identified in this study (thin gauge, non-weldable, grade 3 or 4), the potential product applications are severely limited. The inability to reliably meet the properties of grade 2 metal strips excludes many uses of titanium metal strips. Consequently, it is emphasized that efforts need to be directed at improving the quality of low-cost powders and developing rolling practices to produce thicker gauge metal strips with desirable properties.
Highlights
Direct powder rolling (DPR) is the feeding of metal powder into a rolling mill where it is cold compacted into a “green” strip
The low–chloride containing specimens used by Greenfield et al [80] and Muth et al [38] were made from powders that are not suitable for a commercial direct powder rolling (DPR) operation, as they are either too expensive (HDH derived from wrought product), developmental and not readily available (Armstrong), or not compatible with the process
Applications for thin gauge grade 3 and 4 product are limited, as these grades are typically selected for thicker product where greater strength is a requirement
Summary
Direct powder rolling (DPR) is the feeding of metal powder into a rolling mill where it is cold compacted into a “green” strip (not yet heat treated). The roll compaction of powder is thought to be a more cost-effective, direct route to producing flat product of near final thickness. It is attractive for titanium given that the existing wrought method of melting sponge to ingot followed by rolling to slab, to plate, and to thin gauge sheet is an energy and capital-intensive process. The present review is pertinent to inform researchers who are seeking ways to reduce the production costs of titanium metal strips, and the limitations that might arise in choosing the direct powder rolling process route. (c) Lastly, what range of potential product applications could be suitable for DPR products?.
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