Identifying Challenges to the Commercial Viability of Direct Powder Rolled Titanium: A Systematic Review and Market Analysis

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.

Sintering High Green Density Direct Powder Rolled Titanium Strips, in Argon Atmosphere

“…The current cost of titanium sheet that is produced from the wrought-ingot process, in the size range of 1 mm or less, is between 100 and 200 $/kg, based on 2020 Chinese prices [6]. In comparison, the cost of hydride-dehydride titanium (Ti-HDH) powder varies between 25 and 75 $/kg, based on 2020 Chinese prices [6].…”

“…The current cost of titanium sheet that is produced from the wrought-ingot process, in the size range of 1 mm or less, is between 100 and 200 $/kg, based on 2020 Chinese prices [6]. In comparison, the cost of hydride-dehydride titanium (Ti-HDH) powder varies between 25 and 75 $/kg, based on 2020 Chinese prices [6]. Thus, there is significant room for DPR titanium sheet to be potentially cost-competitive against titanium sheet produced from the wrought-ingot process.…”