Near net shape manufacturing using powder metallurgy (P/M) technology and processes can significantly reduce material waste and cost during... Show moreNear net shape manufacturing using powder metallurgy (P/M) technology and processes can significantly reduce material waste and cost during component fabrication. This study includes all the efforts to evaluate near net shape consolidation processes utilizing several different commercially pure titanium (CP-Ti) powders, focusing on the one produced by Armstrong Process® technology. Powder characteristics were studied in terms of morphology, particle size distribution, apparent and tap densities, and chemistry. Desired particle size distributions and higher powder densities were observed for HDH powders, while unique coral-like morphology was examined for the Armstrong Process® powder. Ball milling of the Armstrong Process® powder was systematically investigated by evaluating the impact on the particle size distribution, powder density and chemistry. Cold-uniaxial compaction of the milled powders was also evaluated in terms of theoretical density and green strength as a function of compaction pressure and lubrication techniques. Green densities were varied from 79 % to 91% for different powder compacts in different compaction conditions. Excellent green compaction of 145 MPa was approached by green compacts of Armstrong Process® powder. Sinter processing of the green compacts was investigated to approach relatively advanced tensile and flexural properties as a function of process temperature, time and heating rate. Near net-shape components which were fabricated by pressing and sintering were shown to achieve near-full densification with up to 97% of the theoretical density. Properties of P/M materials after the consolidation process were characterized and compared to those of conventionally produced materials. M.S. in Materials Science and Engineering, July 2011 Show less
