Titanium has been identified as one of the key materials with a high strength to weight ratio that can reduce the weight of components and... Show moreTitanium has been identified as one of the key materials with a high strength to weight ratio that can reduce the weight of components and thereby reduce energy consumption. Single press and sinter as a powder metallurgy technique has the potential to provide cost effective components. Armstrong prealloyed Ti6Al4V, HDH prealloyed Ti6Al4V, HDH blended Ti6Al4V powder and their mixtures were pressed and sintered at different conditions. The chemistry, mechanical and microstructural properties have been investigated to establish optimum processing parameters. Sintered parts were sent to Oshkosh Truck to test and compared with aluminum and steel parts. The Titanium and Ti6Al4V parts were successfully applied and tested. All the specimens passed the load test without failures. The sintering mechanisms of Armstrong prealloyed Ti6Al4V powder were investigated. At relative sintered densities of 75% to 90% (around 900°C), surface diffusion cooperate with grain boundary diffusion, which leads to densification of the powder compact. Around 900°C, grain boundary diffusion controls the sintering process. At 1000°C, boundary diffusion made little contribution to the densification of the Ti6Al4V powder compact. Above 900°C and below 91% sintered density, boundary diffusion controls sintering. Lattice diffusion dominates the densification process at higher temperatures (1100°C~1300°C). The sintering of master alloy blended Ti6Al4V powder has been investigated in order to elucidate the mechanism of sintering. Both blended powder compacts and diffusion couples were investigated using backscattered imaging and energy xvi dispersive analysis to determine the phases present and diffusion path on sintering at 1000ºC and 1100ºC. It is shown that transient liquid phase sintering does not occur and the reason for the rapid sintering of this material is due to enhanced diffusion kinetics resulting from a combination of the concentration gradient and stress induced by a phase transformation in the ternary system. PH.D in Materials Science and Engineering, May 2013 Show less
