In situ synthesis and regulation of spherical Ti6Al4V powder by calciothermic self-propagating metallurgy

In this paper, spherical Ti6Al4V alloy powder was successfully prepared by calciothermic self-propagating rapid reaction method, in which TiO2, V2O5, Al and Ca were used as raw materials. The reduction reaction can be completed in minutes with no need for any external energy and additives in the reaction process. By investigating the influence of the additives, the amount of reductant Ca added, the reaction pressure and the particle size of Ca, on the composition as well as the morphology of the product, the optimal alloy powder with an low oxygen content of 0.21 wt.% was obtained, whose average particle size and specific surface area were 15.28 μm and 0.284 m2/g respectively. Moreover, this research implied the adiabatic temperature of the system and the liquid Ca are the main factors that pose influence to the powder morphology during sintering-reduction-spheroidization-solidification process. Compared with the traditional Ti6Al4V alloy powder preparation process, this process stands out with characteristics of high purity, short production cycle and environmental friendliness, which show high commercialization potential for industrial preparation of Ti6Al4V and similar alloy powders.