Powder metallurgy (PM) is an attractive technology for manufacturing net-shape titanium-based components. However, it is challenging to make PM titanium products competitive in terms of mechanical properties. This article gives an overview of the current challenges in PM titanium and the best strategies to overcome them by alloying. By adding suitable alloying elements the properties of PM titanium components can be enhanced. The use of sintering aids helps to control the typical residual porosity of PM titanium alloys. Furthermore, controlling microstructure by alloying offers the possibility to go for high performance applications. Moreover, ductility is improved by adding elements that scavenge oxygen. A favorable selection of alloying elements offers a practical and competitive approach to meet the mechanical requirements in future PM titanium applications.

Abstract. TiNi shape-memory properties are successfully used today for the fabrication of various technical devices. The limited machinability and high cost of TiNi encourage the use of near-net shape production techniques such as metal injection moulding. In this work TiNi alloys tensile test specimens are produced by metal injection moulding from pre-alloyed powders. A binder based on a mixture of polyethylene, paraffin wax and stearic acid is used. Parts with a density of about 96.6% of theoretical density are obtained. Scanning electron microscopy coupled with EDX measurements reveals a microstructure consisting of a TiNi matrix with small Ti 4 Ni 2 O x and TiC inclusions. DSC and X-ray diffraction observations indicate the presence of additional Ni 4 Ti 3 precipitates. The parts exhibit full superelasticity at room temperature even for strains of up to 4%, without the need for additional thermal post-treatments. Ultimate tensile strengths up to 980 MPa are obtained.

Abstract.One of the challenges in PM Ti alloys is to control the impurities level. Oxygen affects the microstructure and the mechanical properties of titanium alloys. Ti-6Al-7Nb is a promising alloy to use in PM due to its outstanding biocompatibility and mechanical properties required for load bearing medical implants. In this work, the influence of the impurities content on the ductility, fatigue resistance and microstructure of Ti-6Al-7Nb alloy processed by metal injection moulding was examined. Tensile and fatigue specimens were manufactured using Ti-6Al-7Nb gas atomized powder. Depending on the thermal treatment time, various oxygen contents were introduced into the specimens. The resulting oxygen content was determined by melt extraction technique. Tensile tests and high cycle four-point bending fatigue tests at room temperature were performed. First studies about the effect of oxygen content on crack initiation and propagation were done by the observation of microstructures and fractured surfaces using light and electron microscopy (SEM).

One strategy to make PM titanium components competitive in terms of mechanical properties is the addition of suitable alloying elements. PM offers the possibility to adapt the alloy composition in order to achieve the required properties. In this study, different alloying elements were introduced into α/β titanium alloys and fatigue behaviour was evaluated. Four-point bending fatigue tests with a stress ratio of 0.2 were performed on specimens manufactured by metal injection moulding (MIM) and shot peening. Results showed an enhanced sintering activity of Ti-6Al-7Nb by adding small amounts of iron. The impact on fatigue properties was evaluated. The increase of oxygen in Ti-6Al-7Nb from 0.15 wt.% to 0.45 wt.% caused a decrease in elongation from 16% to 6%. However the fatigue strength at 107cycles is just slightly reduced from 450 to 350 MPa. The addition of 0.5 wt.% yttrium powder to gas atomized Ti‑6Al‑4V powder led to a noticeable refinement of the microstructure of the sintered parts, due to the formation of Y2O3particles, which hinder grain growth. In spite of a slightly higher residual porosity, the microstructural refinement increased the fatigue strength at 107cycles from 450 to 470 MPa. At 106cycles, the fatigue strength increased even from 705 to 765 MPa. The addition of yttrium did not result in a higher oxygen pick up, which indicates a scavenging of oxygen from the titanium matrix by formation of Y2O3during sintering. Contrary to the fatigue strength results, the scavenging effect led to a decrease in tensile strength of about 70 MPa. The microstructure of fatigue-tested specimens was characterized by using optical and scanning electron microscopy.

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