Development of the Fray-Farthing-Chen Cambridge Process: Towards the Sustainable Production of Titanium and Its Alloys

Hu, Di; Dolganov, Aleksei; Ma, Mingchan; Bhattacharya, Biyash; Bishop, Matthew; Chen, George

doi:10.1007/s11837-017-2664-4

Cited by 59 publications

(40 citation statements)

References 84 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…2; [3140]). The current efficiency ξe for Ti extraction using this process is low (< 2000 ppm oxygen, ξe = 32.3 %) but relatively high for Cr extraction (< 2000 ppm oxygen, ξe > 70 %) [41]. Although oxygenevolving inert anodes could improve ξe, the several 100 patents describing such anodes in Hall-Héroult cells are not totally satisfactory [6].…”

Section: Ffc Cambridge Processmentioning

confidence: 92%

Molten Salt Electrometallurgy

Osarinmwian

2019

Preprint

View full text Add to dashboard Cite

Molten salt is a wonder liquid with many superlatives to its name. It possesses low volatility, good heat transfer capacity, high electrical and thermal conductivity, radiation insensitivity, and low viscosity up to 1773 K. It is a universal electrolyte, chemical reaction medium, and energy storage medium while opening new opportunities for ecologically-safe, economically favourable methods for materials processing. Predominant Coulomb interaction between particles in molten salt makes it the best medium for physical and computer simulation of liquid structure and properties. Here we investigate molten salt electrometallurgy and related processes, and attempt to identify future mathematical modelling directions in which the field is likely to develop.

show abstract

Section: Ffc Cambridge Processmentioning

confidence: 92%

Molten Salt Electrometallurgy

Osarinmwian

2019

Preprint

View full text Add to dashboard Cite

show abstract

“…In addition, the development and insertion of new titanium-synthesis and wrought processing techniques may be accelerated using fundamental understanding derived from the TMP of conventional (ingot-metallurgy) products. These newer approaches include so-called ''meltless'' titanium [265,266] in which titanium oxides are reduced directly without expensive intermediary steps (such as the production of TiCl 4 ); the methods yield a powder product that is consolidated by subsequent solid-state deformation processes. The formulation of new a/b Ti compositions that provide improved cold workability, thus enabling lower-cost production of thin-gage sheet products, is also a promising new technology for the titanium industry.…”

Section: B Rapid Heat Treatmentmentioning

confidence: 99%

An Overview of the Thermomechanical Processing of α/β Titanium Alloys: Current Status and Future Research Opportunities

Semiatin

2020

Metall Mater Trans A

155

View full text Add to dashboard Cite

Current understanding of the principles underlying the thermomechanical processing (TMP) of a/b titanium alloys is reviewed. Attention is focused on the formulation of constitutive descriptions for plastic flow under hot-working conditions, the evolution of microstructure, the occurrence of defects, and novel/emerging TMP techniques. With regard to constitutive behavior, descriptions of the plastic flow of the individual phases and two-phase alloys per se are summarized. The important influence of phase morphology, size, and volume fraction on plastic flow is emphasized. Mechanisms which underlie microstructure evolution include beta recrystallization (in the high-temperature b field), the development of dislocation substructure and its effect on dynamic and static spheroidization of colony microstructures (in the two-phase field), static and dynamic coarsening of primary a, and the development of deformation and transformation textures. In the area of defects, the effect of TMP variables and starting microstructure on the formation of cavities, the persistence of microtexture, and the development of undesirably-coarse b grain structures are described. The current status of relatively new processing techniques for a/b titanium alloys such as low-temperature superplastic forming and solid-state joining (via linear friction or friction-stir methods) are also briefly reviewed. Last, R&D which could help to resolve deficiencies in the current knowledge base for TMP of a/b titanium alloys are summarized for each of the areas.

show abstract

“…To assess projected costs, a life cycle analysis study estimated that Ti production via the FFC-Cambridge process could reduce 'gross energy requirements' and 'global warming potential' by 10 -15% compared to conventional Kroll production; with further reductions of 30-35% achievable using lower TiO 2 purity feedstock [18]. Developments to the process have been investigated to make it even more attractive for Ti extraction, including use of more sustainable feedstocks, improving current efficiencies, use of inert anodes which prevent CO 2 generation and production of near-net shape components from shaped oxide precursors [15,[19][20][21]. A recent study on the use of shaped oxide via the 'Near-net-shape Electrochemical Metallisation (NEM) process' attempted to quantify the environmental impacts of components produced using this method, compared to electron beam melting of Kroll derived, gas atomised powders.…”

Section: Ti Extraction Via the Ffc-cambridge Processmentioning

confidence: 99%

Direct electrochemical production of pseudo-binary Ti–Fe alloys from mixtures of synthetic rutile and iron(III) oxide

Graham

Benson²,

Jackson

2020

J Mater Sci

View full text Add to dashboard Cite

Combining the FFC-Cambridge process with field-assisted sintering technology (FAST) allows for the realisation of an alternative, entirely solid-state, production route for a wide range of metals and alloys. For titanium, this could provide a route to produce alloys at a lower cost compared to the conventional Kroll-based route. Use of synthetic rutile instead of high purity TiO2 offers further potential cost savings, with previous studies reporting on the reduction of this feedstock via the FFC-Cambridge process. In this study, mixtures of synthetic rutile and iron oxide (Fe2O3) powders were co-reduced using the FFC-Cambridge process, directly producing titanium alloy powders. The powders were subsequently consolidated using FAST to generate homogeneous, pseudo-binary Ti–Fe alloys containing up to 9 wt.% Fe. The oxide mixture, reduced powders and bulk alloys were fully characterised to determine the microstructure and chemistry evolution during processing. Increasing Fe content led to greater β phase stabilisation but no TiFe intermetallic phase was observed in any of the consolidated alloys. Microhardness testing was performed for preliminary assessment of mechanical properties, with values between 330–400 Hv. Maximum hardness was measured in the alloy containing 5.15 wt.% Fe, thought due to the strengthening effect of fine α phase precipitation within the β grains. At higher Fe contents, there was sufficient β stabilisation to prevent α phase transformation on cooling, leading to a reduction in hardness despite a general increase from solid solution strengthening.

show abstract

Development of the Fray-Farthing-Chen Cambridge Process: Towards the Sustainable Production of Titanium and Its Alloys

Cited by 59 publications

References 84 publications

Molten Salt Electrometallurgy

Molten Salt Electrometallurgy

An Overview of the Thermomechanical Processing of α/β Titanium Alloys: Current Status and Future Research Opportunities

Direct electrochemical production of pseudo-binary Ti–Fe alloys from mixtures of synthetic rutile and iron(III) oxide

Contact Info

Product

Resources

About