In the present study, porous titanium based composite has been developed by powder metallurgy route using cenosphere and sodium chloride (NaCl) as space holders. The effect of cenosphere particle size and sintering parameters on density, microstructure, wear and corrosion resistance has been studied. The microstructure of the composite consists of uniform distribution of cenosphere in a-Ti matrix with the presence of few TiO 2 and SiO 2 phases. The density of the composites varies from 1331 to 1812 kg m 23 . The kinetics and mechanism of fretting wear against hardened steel ball (at an oscillation frequency of 10 Hz) as a function of applied load (5 and 10 N) have been studied. There is a significant reduction in coefficient of friction in porous composite as compared to that of pure titanium. There is improvement in corrosion resistance in porous titanium composites as compared to as received titanium in 3.56 wt-% NaCl solution.

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The present study includes a detailed analysis of titanium based composite foam developed by powder metallurgy route and to understand the role of process parameters and the particle size of the space holder (cenosphere) on the kinetics and mechanism of wear. Cenosphere of varying particle size (<150 μm; 150-212 μm; > 212 μm) were mixed with titanium in a ratio of 1:3, compacted at 100 MPa and sintered at 1000°C and 1200°C for a period of 2,4 & 6 hrs in each temperature. The kinetics of wear and frictional coefficient of sintered composites were evaluated by reciprocating wear testing machine against diamond indenter at applied load of 10 N. The mechanism of wear was studied by a detailed analysis of the post wear microstructure. The composite foam with cenosphere particle size in the range of 150-212 μm showed minimum wear rate. The mechanism of wear was found to be a combination of adhesive and abrasive.

The present study concerns detailed microstructural investigation and property evaluation of titanium-cenosphere composite developed by powder metallurgy route. The main process variables for the development of titanium-cenosphere composite were cenosphere particle size, sintering time, and sintering temperature. Followed by sintering, a detailed characterization of the sintered parts in terms of density, microstructure, composition and phase has been carried out. The compressive strength of the sintered component has also been evaluated in details. The density of the sintered pellets varied with process parameters and is significantly reduced (2.5-2.11 g/cm3) as compared to as-received titanium (4.5 g/cm3). The compressive yield strength of the sintered pellet is reduced as compared to as-received Ti-6Al-4V.