A Method for the Production of Titanium-Tantalum Binary Alloys Using the Metalysis-FFC Process

Abstract

Titanium-tantalum alloys have historically been difficult to produce using conventional techniques due to the large difference in melting point and poor interdiffusivity rates of the two elements, leading to large levels of segregation. In this work we have investigated using the Metalysis-FFC process to overcome this problem. The Metalysis-FFC process is an electrochemical process where metal oxides are reduced by acting as a cathode in an electrolytic cell combined typically with a graphite anode and molten calcium chloride electrolyte. Previous work has proven that the process works when applied to mixed oxides to produce alloys. The reduction process is performed in the solid state and so negates the problems associated with traditional melting practices such as segregation and evaporation losses. In this work we have been able to successfully produce a range of Ti-Ta alloy powders from pure titanium to pure tantalum in 10 wt% increments using the Metalysis-FFC process. Moreover, energy dispersive spectroscopy analysis of the powders suggests uniform distribution of titanium and tantalum within all compositional ranges, suggesting the Metalysis-FFC process has the potential to be a transformative manufacturing methodology for producing titanium-tantalum alloys.