The commercial feasibility and potential product applications of direct powder rolled titanium
Titanium is known for its high strength-to-weight ratio and good corrosion resistance but it has seen limited use - outside of the aerospace industry - due to high processing and fabrication costs. There has been much interest in the use of powder metallurgy (PM) as a viable, cost reduction alternative to conventional ingot processes. In particular, direct powder rolling (DPR) is a promising form of consolidation as it is the most direct method of producing flat product. However, it is still not widely used in industry.
This thesis aims to conduct a comprehensive review by analysing data from past efforts to produce sheet, plate or foil from this method. Identification of the critical process parameters, limitations and effects of factors such as porosity, oxygen and microstructure on the final properties will help to understand the potential applications of the final product. Since DPR is not the only PM route to producing flat product, the question is not only whether it is more economical than conventional ingot routes, but also whether it out performs other PM routes such as hot roll densification and hot or cold isostatic pressing.