Titanium - Production and Fabrication

Production and Fabrication

The processing of titanium metal occurs in 4 major steps: reduction of titanium ore into "sponge", a porous form; melting of sponge, or sponge plus a master alloy to form an ingot; primary fabrication, where an ingot is converted into general mill products such as billet, bar, plate, sheet, strip, and tube; and secondary fabrication of finished shapes from mill products.

Because the metal reacts with oxygen at high temperatures it cannot be produced by reduction of its dioxide. Titanium metal is therefore produced commercially by the Kroll process, a complex and expensive batch process. (The relatively high market value of titanium is mainly due to its processing, which sacrifices another expensive metal, magnesium.) In the Kroll process, the oxide is first converted to chloride through carbochlorination, whereby chlorine gas is passed over red-hot rutile or ilmenite in the presence of carbon to make TiCl₄. This is condensed and purified by fractional distillation and then reduced with 800 °C molten magnesium in an argon atmosphere.

A more recently developed method, the FFC Cambridge process, may eventually replace the Kroll process. This method uses titanium dioxide powder (which is a refined form of rutile) as feedstock to make the end product which is either a powder or sponge. If mixed oxide powders are used, the product is an alloy manufactured at a much lower cost than the conventional multi-step melting process. The FFC Cambridge process may render titanium a less rare and expensive material for the aerospace industry and the luxury goods market, and could be seen in many products currently manufactured using aluminium and specialist grades of steel.

Common titanium alloys are made by reduction. For example, cuprotitanium (rutile with copper added is reduced), ferrocarbon titanium (ilmenite reduced with coke in an electric furnace), and manganotitanium (rutile with manganese or manganese oxides) are reduced.

2 FeTiO₃ + 7 Cl₂ + 6 C → 2 TiCl₄ + 2 FeCl₃ + 6 CO (900 °C)

TiCl₄ + 2 Mg → 2 MgCl₂ + Ti (1100 °C)

About 50 grades of titanium and titanium alloys are designated and currently used, although only a couple of dozen are readily available commercially. The ASTM International recognizes 31 Grades of titanium metal and alloys, of which Grades 1 through 4 are commercially pure (unalloyed). These four are distinguished by their varying degrees of tensile strength, as a function of oxygen content, with Grade 1 being the most ductile (lowest tensile strength with an oxygen content of 0.18%), and Grade 4 the least (highest tensile strength with an oxygen content of 0.40%). The remaining grades are alloys, each designed for specific purposes, be it ductility, strength, hardness, electrical resistivity, creep resistance, resistance to corrosion from specific media, or a combination thereof.

The grades covered by ASTM and other alloys are also produced to meet Aerospace and Military specifications (SAE-AMS, MIL-T), ISO standards, and country-specific specifications, as well as proprietary end-user specifications for aerospace, military, medical, and industrial applications.

In terms of fabrication, all welding of titanium must be done in an inert atmosphere of argon or helium in order to shield it from contamination with atmospheric gases such as oxygen, nitrogen, or hydrogen. Contamination will cause a variety of conditions, such as embrittlement, which will reduce the integrity of the assembly welds and lead to joint failure. Commercially pure flat product (sheet, plate) can be formed readily, but processing must take into account the fact that the metal has a "memory" and tends to spring back. This is especially true of certain high-strength alloys. Titanium cannot be soldered without first pre-plating it in a metal that is solderable. The metal can be machined using the same equipment and via the same processes as stainless steel.